SECTION 7B - AUTOMATIC TRANSAXLE

WARNING:

For vehicles equip ped wit h Suppl ement Restraint (Airbag) System

• Service on and around the airbag system components or wiring must be performed only by

an authorised H OLDEN retailer. R efer to Section 10B AIRBAG SYSTEM COMP ONENTS AND

WIRING LOCATION VIEW in GENERAL DESCRIPTION in order to confirm whether you are

performing service on or near the airbag system components or wiring. Please observe all

W ARNINGS and SERVICE PRECAUTIONS, refer to Section 10B ON-VEHICLE SERVICE before

performing service on or around the airbag system components or wiring. Failure to follow

WARNINGS could result in unintentional activation of the system or could render the syste m

inoperative. Either o r t hese two conditions may result in severe injury.

• Techni cal servi ce work must not be started for at least 90 seconds after the igni tion switch is

turned to the “LOCK” position and the negative cable is disconnected from the battery. Oth-

erwise, the system may be activated by reserve energy in the Sensing and Diagnostic Mod-

ule (SDM).

IMPORTANT:

Prior to connecting Tech 2 to the vehicle, refer to Section 0C TECH 2.

1. GENERAL DESCRIPTION

1.1 SPECIFICATIONS

1.2 CLUTCH/BRAKE/PLANETARY GEAR

Functions

1.3 TABLE OF COMPONENT OPERATION

1.4 ELECTRONIC SHIFT CONTROL SYSTEM

1.5 TRANSMISSION CONTROL MODULE

(TCM)

Operation Of Shift Solenoid Valves,

Timing Solenoid Valve and TCC

Solenoi d Val ve 3

Automatic Gear Shift Diagram

Gear Shift Diagram [A] and TCC

Lock-up Diagram [B]

2. DIAGNOSIS

2.1 GENERAL DESCRIPTION

2.2 ON-BOARD DIAGNOSTIC SYSTEM

2.3 PRECAUTION IN DIAGNOSING

TROUBLE

2.4 AUTOMATIC TRANSAXLE DIAGNOSTIC

FLOW TABLE

Customer Problem Inspection Form

(Example)

2.5 O/D OFF - LAMP CHECK

2.6 DIAGNOSTIC TROUBLE CODE (DTC)

CHECK

DTC Check Using Tech 2

DTC Check Not Using Tech 2

2.7 DIAGNOSTIC TROUBLE CODE (DTC)

CLEARANCE

DTC Clearance Using Tech 2

DTC Clearance Not Using Tech 2

2.8 DIAGNOSTIC TROUBLE CODE (DTC)

TABLE

2.9 FAIL SAFE TABLE

2.10 VISUAL INSPECTION

2.11 AUTOMATIC TRANSAXLE BASIC

CHECK

2.12 TROUBLE DIAGNOSIS TABLE

Trouble Diagnosis Table-1

Trouble Diagnosis Table-2

Trouble Diagnosis Table-3

2.13 ROAD TEST

Troubleshooting

2.14 MANUAL ROAD TEST

Troubleshooting

2.15 ENGINE BRAKE TEST

Troubleshooting

2.16 STALL TEST

Troubleshooting

2.17 TIME LAG TEST

Troubleshooting

2.18 LINE PRESSURE TEST

Automatic Transmission

Line Pressure

Troubleshooting

2.19 P RANGE TEST

Troubleshooting

2.20 DIAGNOSTIC FLOW TABLE A-1: NO

GEAR SHIFT TO O/D

System Description

Troubleshooting

2.21 DIAGNOSTIC FLOW TABLE A-2: NO

LOCK-UP OCCURS

System Description

Troubleshooting

2.22 DIAGNOSTIC FLOW TABLE A-3: O/D

OFF LAMP CIRCUIT CHECK (O/D OFF

LAMP LIGHTS STEADILY)

Wiri ng Diagra m

Circuit Description

Troubleshooting

2.23 DIAGNOSTIC FLOW TABLE A-4: O/D

OFF LAMP CIRCUIT CHECK (O/D OFF

LAMP DOES NOT LIGHT AT ALL)

Wiri ng Diagra m

Circuit Description

Troubleshooting

2.24 DIAGNOSTIC FLOW TABLE A-5: TCM

POWER AND GROUND CIRCUIT

CHECK

Wiri ng Diagra m

Troubleshooting

2.25 DTC P0705/DTC NO.34 TRANSMISSION

RANGE SENSOR CIRCUIT

MALFUNCTION

Wiri ng Diagra m

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.26 DTC P0710/DTC NO.36 OR 38

TRANSMISSION FLUID

TEMPERATURE SENSOR CIRCUIT

MALFUNCTION

Wiri ng Diagra m

DTC Detecting Condition

and Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.27 DTC P0715/DTC NO.14 INPUT/TURBINE

SPEED SENSOR CIRCUIT

MALFUNCTION

Wiri ng Diagra m

DTC Detecting Condition

and Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.28 DTC P0720/DTC NO.31 OUTPUT SPEED

SENSOR (VSS) CIRCUIT

MALFUNCTION

Wiri ng Diagra m

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.29 DTC P0725/DTC NO.35 ENGINE SPEED

INPUT CIRCUIT MALFUNCTION

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.30 DTC P0743/DTC NO.25 OR NO.26 TCC

SYSTEM ELECTRICAL

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.31 DTC P0748/DTC NO.41 OR NO.42

PRESSURE CONTROL SOLENOID

ELECTRICAL

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.32 DTC P0753/DTC NO.21 OR NO.22 SHIFT

SOLENOID-A (NO.1) ELECTRICAL

2.33 DTC P0758/DTC NO.23 OR NO.24 SHIFT

SOLENOID-B (NO.2) ELECTRICAL

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.34 DTC P0785/DTC NO.13 TIMING

SOLENOID

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.35 DTC P1700/DTC NO.32 OR NO.33

THROTTLE POSITION SIGNAL

CIRCUIT MALFUNCTION

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.36 DTC P1702/DTC NO.52 INTERNAL

MALFUNCTION OF TCM

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.37 DTC P1705/DTC NO.51 ENGINE

COOLANT TEMPERATURE SIGNAL

CIRCUIT MALFUNCTION

Wiring Diagram

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.38 DTC P1730/DTC NO.64 ENGINE TORQUE

SIGNAL CIRCUIT MALFUNCTION

Wiri ng Diagra m

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.39 DTC P1895/DTC NO.27 TORQUE

REDUCTION SIGNAL CIRCUIT

MALFUNCTION

Wiri ng Diagra m

DTC Detecting Condition and

Trouble Area

DTC Confirmation Procedure

Troubleshooting

2.40 TECH 2 DATA

Tech 2 Data Definitions

2.41 INSPECTION OF TCM AND ITS

CIRCUITS

Inspection

Terminal Arrangement of TCM

Connector (Viewed From

Harness Side)

3. ON-VEHICLE SERVICE

3.1 MAINTENANCE SERVICE

Fluid Level Check at Normal

Operating (Hot) Temperature (Hot

Check)

Fluid Level Check at Room (Cold)

Temperature (Cold Check)

Fluid Change

A/T Fluid Cooler Hoses

3.2 SELECTOR LEVER

Inspection

3.3 SELECT CABLE

Removal

Installation

Adjustment

3.4 TRANSMISSION RANGE SENSOR

(SHIFT SWITCH)

Adjustment And Inspect ion

3.5 OUTPUT SHAFT SPEED SENSOR (VSS)

Removal

Inspection

Installation

3.6 INPUT SHAFT SPEED SENSOR

Inspection

Removal

Installation

3.7 THROT TLE POSITION SENSOR

Inspection

3.8 ENGINE COOLANT TEMPERATURE

SENSOR

Inspection

3.9 O/D OFF SWITCH

Inspection

3.10 SOLENOID VALVES (SHIFT SOLENOID

VALVES, TCC SOLENOID VALVE AND

TIMING SOLENOID VALVE)

Removal

Inspection

Operation Check

Timing Solenoid Valve (Both Denso

and Aisin Type)

Installation

3.11 PRESSURE CONTROL SOLENOID

VALVE

Removal

Inspection

Installation

3.12 TRANSMISSION CONTROL MODULE

(TCM)

Removal

Installation

Learning Control Initialisation

Brief Learning

3.13 A/T RELAY

Inspection

3.14 TRANSMISSION FLUID TEMPERATURE

SENSOR

Inspection

Installation

3.15 DIFFERENTIAL SIDE OIL SEAL

Replacement

3.16 AUTOMATIC TRANSAXLE ASSEMBLY

Components

Removal

Installation

4. UNIT REPAIR

4.1 PRECAUTIONS

4.2 PART INSPECTION AND CORRECTION

TABLE

4.3 UNIT DISASSEMBLY

Components

Disassembly

Inspection

4.4 DISASSEMBLY/ASSEMBLY OF

SUBASSEMBLY

Oil Pump

Disassembly

Inspection

Assembly

Dir ect Clutch

Preliminary Check

Disassembly

Inspection

Assembly

Forward and Reverse Clutch

Preliminary Check

Disassembly

Inspection

Assembly

2nd Brake Piston

Disassembly

Assembly

Transaxle Rear Cover Assembly

(O/D and 2nd Coast Brake Piston

Disassembly

Inspection

Assembly

4.5 DIFFERENTIAL ASSEMBLY

Disassembly

Inspection

Assembly

Countershaft

Disassembly

Assembly

Valve Body

Disassembly

Assembly

Torque Converter Housing

Transaxle Case

Adjustment Before Unit Assembly

4.6 Unit Assembly

5. SPECIAL TOOLS

6. REQUIRED SERVICE MATERIAL

1. GENERAL DESCRIPTION

The automatic transaxle is an electronically controlled, fully automatic transaxle with 3 forward speeds plus

overdrive (O/D) and 1 reverse speed.

The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically con-

trolled lock-up mechanism.

The gear change device consists of a ravigneau type planetary gear unit, 3 multiple disc type clutches, 3 mul-

tiple disc type brakes and 2 one-way clutches.

The hydraulic pressure control device consists of a valve body assembly, pressure control solenoid valve (lin-

ear solenoid), 2 shift solenoid valves, TCC (lock-up) solenoid valve and a timing solenoid valve. Optimum line

pressure, complying with engine torque, is produced by the pressure control solenoid valve depending on a

contr ol s ignal from the tr ansmi ss ion control m odu le (T CM). T his makes it pos s ible to c ontrol the li ne press ur e

with a hi gh degree of accuracy i n accordan ce with eng ine power and r unning c onditions, a chieving s mooth

shifting characteristics and high efficiency.

A clutc h-to-clu tch control system i s provided f or shifting betwee n 3rd gear and 4t h gear. This clutch -to-clutc h

control system functions optimally, so that the hydraulic pressure controls indicated below are activated.

i. When upshifting from 3rd gear to 4th gear, to adjust the drain hydraulic pressure when releasing the

forward clutch, a timing solenoid valve is used to switch a hydraulic passage via an orifice to ano ther

passage during shifting.

ii. When downsh ifting from 4th ge ar to 3rd gear, to adjust the line pr essure applied to the forwa rd clutch

when it is engaged, a timing solenoid valve is used to switch a hydraulic passage via an orifice to

another passage during shifting.

iii. When upshifting from 3rd gear to 4th gear with the engine throttle opened, to optimise the line pressure

applied to the forward clutch when it is released, the learning control is processed to compensate the

switching timing solenoid when shifting.

iv. When downshifting from 4th gear to 3rd gear with the engine throttle opened, to optimise the line pres-

sure a pplie d to the fo rward cl utch wh en enga ging the forward c lutc h, the lea rning c ontrol is proc essed

to compensate the line pressure when shifting.

Employing a ravigneau type planetary gear unit, this clutch-to-clutch control system greatly simplifies the con-

struction to produce a lightweight and compact transaxle.

A line pressure learning control is conducted to provide optimum shifting time when upshifting with the engine

throttl e op ened . If a l ong u pshifting time is dete cte d, the su bse que nt l ine press ure applie d duri ng upshi fting is

intensified. Conversely, if a short upshifting time is detected, the subsequent line pressure applied during

upshifting is lessened.

Legend

1. Drive plate 10. Planet carrier 21. Rear sun gear

2. Torque converter clutch (TCC) 11. 1st and reverse brake 22. Front sun gear

3. Torque converter 12. Ring gear 23. Short planet pinion

4. Input shaft 13. Long planet pinion 24. Countershaft

5. Oil pump 14. One-way clutch No.2 25. Reduction driven gear

6. Direct clutch drum (doubles

as sensor rotor for input shaft

speed sensor)

15. Second brake 26. Differential case assembly

16. One-way clutch No.1 27. Final gear

17. O/D and 2nd coast brake 28. Output shaft speed sensor

(VSS ) driv e gear

7. Direct clutch 18. Intermediate shaft

8. Parking lock gear 19. Forward clutch

9. Reduction drive gear 20. Reverse clutch

1.1 SP ECIFICATIONS

Item Specifications

Torque

converter Type

Stall torque ratio 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism)

1.9 – 2.1

Oil pump Type

Drive system Internal involute gear type oil pump (non crescent type)

Engine driven

Gear

change

device

Type Forward 4-step, reverse 1-step planetary gear type

Shift position P range Gear in neutral, output shaft fixed, engine start

R range Reverse

N range Gear in neutral, engine start

D range

(O/D ON) Forward 1st ↔ 2nd ↔ 3rd ↔ 4th (O/D)

automatic gear change

D range

(O/D OFF) Forward 1st ↔ 2nd ↔ 3rd ← 4th

automatic gear change

2 range Forward 1st ↔ 2nd ← 3rd

automatic gear change

L range Forward 1st ← 2nd ← 3rd reduction, and fixed at 1st

gear

Gear

ratio 1st 2.875 Number of teeth Front sun gear: 24

2nd 1.568 Rear sun gear: 30

3rd 1.000 Long planet pinion: 20

4th

(overdrive

gear)

0.697 Short planet pinion: 19

Ring gear: 69

Reverse

(reverse gear) 2.300

Control elements Wet type multiple-disc clutch... 3 sets

Wet type multiple-disc brake... 3 sets

One-way clutch... 2 sets

Reduction gear ratio 1.019

Final gear reduction

ratio 4.277

Lubrication Lubrication system Force feed system by oil pump

Cooling Cooling system Radiator assisted cooling (water-cooled)

Fluid used DEXRON



-III

1.2 CLUTCH/BRAKE/PLANETARY GEAR

Legend

FUNCTIONS

1. Input shaft and intermediate 7. Final driven gear C3: Reverse clutch

shaft 8. Reduction driven gear B1: O/D and 2nd coast brake

2. Reduction drive gear 9. Front sun gear B2: 2nd brake

3. Planet carrier 10. Ring gear B3: 1st and reverse brake

4. Short planet pinion 11. Rear sun gear F1: One-way clutch No.1

5. Long planet pinion C1: Forward clutch F2: One-way clutch No.2

6. Final drive gear C2: Direct clutch

PART NAME FUNCTION

Forward clutch Meshes intermediate shaft and front sun gear

Direct clutch Meshes input shaft and planet carrier

Reverse clutch Meshes intermediate shaft and rear sun gear

O/D and 2nd coast brake Fixes rear sun gear

2nd brake Fixes rear sun gear

1st and r everse brake Fixes planet carrier

One-way clutch No.1 Prevents rear sun gear from turning counterclockwise

One-way clutch No.2 Prevents planet carrier from turning counterclockwise

1.3 TABLE OF COMPONENT OPERATI ON

1.4 ELECTRONIC SHIFT CONTROL SYSTEM

Legend

1. Engine 10. Brake light (stop lamp) switch 17. Transmission fluid

temp eratur e se nsor

2. Transaxle 11. Input shaft speed sensor

3. O/D OFF lamp 12. Transmission range sensor 18. TCC (lock-up) solenoid valve

4. Throttle position (TP) sensor 13. Pressure control solenoid 19. Output shaft speed sensor

5. Diagnosis connector No. 2 valve (VSS)

6. A/T relay 14. Shift solenoid valve-A (No.2) 20. Engine coolant temperature

7. TCM 15. Shift solenoid valve-B (No.1) (ECT) sensor

8. ECM 16. Timing solenoid valve 21. Data link connector (DLC)

9. O/D off switch

1.5 TRANSMISS ION CONTROL MODULE (TCM)

Legend

1. TC M 9. ECM 18. Pre ssure control s olenoid

2. Input shaft sp eed sensor 10. Speedometer valve

3. Output shaft speed sensor (in combination meter) 19. A/T

(VSS) 11. Transmission range sensor 20. Data link connector (DLC)

4. O/D off swit ch 12. Backup lamp 21. “O/D OFF” lamp

5. Diagnosis connector No. 2 13. Transmission fluid temperature 22. A/T relay

(colour in Bl ack) sens or 23. Ignition switch

6. Brake light (Stop lamp) 14. Shift solenoid valve-A (No.1) 24. Inhibitor switch

OPERATION OF SHIFT SOLENOID VALVES, TIMING SOLENOID VALVE

AND TCC SOLENOID VALVE

AUTOMATIC GEAR SHIF T DIAGRAM

The automatic shift schedule is shown below. If the selector lever is shifted to L range at a speed

higher than 48 km/h speed, 2nd gear will operate and only down shift to 1st when the vehicle speed

drops below 48 km/h.

Similarly, if the select lever is shifted to 2 range at a speed higher than 95 km/h, 3rd gear will operate

and only down shift to 2nd when the vehicle speed drops below 95 km/h.

7. Brake light switch 15. Shift solenoid valve-B (No.2) 25. Starter motor relay

(Stop lamp switch) 16. Timing solenoid valve 26. Terminal arrangement of TCM

connector

(viewed from harne ss)

8. ABS control module 17. TCC (lock-up) solenoid valve

Valve status

Turn power ON Turn power OFF

Shift solenoid valve-A (No.1) Close Open

Shift solenoid valve-B (No.2) Close Open

Timing solenoid Open Close

TCC (lock-up) solenoid Close Open

Shift

Throttle opening 1→22→33→44→33→22→1

Full throttle km/ h 48 95 No up shift 137 89 38

Closed throttl e km/h 12 24 43 29 18 10

GEAR SHIFT DIAGRAM [A] AND TCC LOCK-UP DIAGRAM [B]

2. DIAGNOSIS

2.1 GENERAL DESCRIPTION

This vehicle is equipped with an electronic transaxle control system, which controls the automatic shift

up and shift down timing, TCC operation, etc. suitable to the vehicle drivin g conditions.

TCM has an On-B oard Diagn osis Syst em which detect s a malfunction in this system.

When diagnosing a trouble in the A/T transaxle, be sure to have full understanding of the outline of

2.2 ON-BOARD DIAGNOSTIC SYSTEM and each item in 2.3 PRECAUTIONS IN DIAGNOSING

TROUBLE and execute diagnosis according to 2.4 AUTOMATIC TRANSAXLE DIAGNOSTIC FLOW

TABLE in this Section to obtain correct result smoothly.

2.2 ON-BOARD DIAGNOSTIC SYSTEM

The TCM has the follow ing functions in the automatic tran-

saxle control system:

• When the ignition switch is turned ON with the O/D

OFF swit ch turned OFF an d no malfunction in the A/T

control system is detected, the O/D OFF lamp (1) lights

for about 2 seconds after the ignition switch is turned

ON then goes OFF for bulb check.

If the O/D off switch is ON, however , the O/D OFF lamp

remains ON to let the driver know that the gear has not

shifted to overdrive (4th gear).

• When the TCM detects a malfunction in the A/T control

system, the O/D OFF lamp (1) flashes and stores the

malfunction DTC in its memory.

• It is possible to communicate with the TCM through the

data link connector (DLC) (1) using Tech 2 (A). (Diag-

nostic information can be checked and erased using

Tech 2.)

• It is also possible to output the DTC indicated by the

flashing O/D OFF lamp with the diagnosis switch termi-

nal (1) of the diagnosis connector No. 2 (2) grounded

(3).

If there is no malfunction DTC is stored in the TCM

memory, DTC No.12 is outputted repeatedly.

If one or more malfunction DTCs are stored in the TCM

memory, they are outputted three times per one code

starting from smallest code number in increasing order.

After all malfunction DTCs are outputted, all malfunc-

tion DTCs are outputted again in the same manner.

2.3 PRECA UTION IN DIAGNOSING TROUBLE

• Do not disc on nec t the connec tors fro m the EC M, th e batt ery c able fr om th e bat tery, the ECM gro und wire

harness from the engine or the main fuse before checking the diagnosis information stored in the ECM

memory.

Disconnection of these items will clear the memorised information in the ECM memory.

• Using Tech 2, the diagno st ic infor matio n stor ed in t he TCM memor y can b e chec ked a nd clea red. Be fore

using Tech 2, be sure to read the Operator’s (instruction) Manual supplied with it carefully to clearly under-

stand its functions and usage.

•Refer to Section 0A, 1.7 PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE before undertaking

inspection and repairs.

• TCM and/or ECM replacement

i. When substituting a known-good TCM and/or ECM, check that all relays and actuators have resis-

tance of the specified value.

Neglecting this check may result in damage to a good TCM and/or ECM.

ii. When replacing the TCM with a used one, all learned contents, which have been stored in the TCM

memory by executing learning control, should be initialised after replacement, refer to LEARNING

CONTROL INITIALISATION in 3.12 TRANSMISSION CONTROL MODULE (TCM) in this Secti on.

Neglecting this initialisation may cause excessive shift shock.

2.4 AUTOMATIC TRANSAXLE DIAGNOSTIC FLOW TABLE

Refer to the following pages for the details of each step

Step Action Yes No

1. Customer Complaint Analysis

Perform customer complaint analysis referring

to the next page.

Was customer complaint analysis performed

according to instruction on the next page?

Go to Step 2. Perform customer com-

plaint analysis.

2. Diagnostic Trouble Code (DTC) Check,

Record and Clear anc e

Check for DTC referring to the next page.

Is there any DTC(s)?

Print DTC or write them

down and clear them by

referring to 2.8 DTC

CLEARANCE in this

Section.

Go to Step 3.

Go to Step 4.

3. Visual Inspection

Perform visual inspection referring to the next

page.

Is there a faulty condition?

Repair or replace

malfunction part.

Go to Step 11.

Go to Step 5.

4. Visual Inspection

Perform visual inspection referring to the next

page.

Is there any faulty condition?

Repair or replace

malfunction part.

Go to Step 11.

Go to Step 8.

5. Trouble Symptom Confirmation

Confirm trouble symptom referring to the next

page.

Is a trouble symptom identified?

Go to Step 6. Go to Step 7.

6. Rechecking and Record of DTC

Recheck for DTC referring to “DTC Check” in

this section.

Are there any DTC(s)?

Go to Step 9. Go to Step 8.

7. Rechecking and Record of DTC

Recheck for DTC referring to “DTC Check” in

this section.

Are there any DTC(s)?

Go to Step 9. Go to Step 10.

8. Automatic Transaxle Basic Inspection and

Trouble Diagnosis Table

Check and repair, refer to 2.11 A/T BASIC

CHECK and 2.12 TROUBLE DIAGNOSIS

TABLE in this Section.

Are the checks and repairs complete?

Go to Step 11. Check and repair

malfunctioning part(s).

Go to Step 11.

9. Troubleshooting for DTC

Check and repair according to applicable DTC

Flow Table.

Are the checks and repairs complete?

Go to Step 11. Check and repair

malfunctioning part(s).

Go to Step 11.

10. Check for Intermittent Problems

Check for intermittent problems, refer to the

next page.

Is there a faulty condition?

Repair or replace mal-

functioning part(s).

Go to Step 11.

11. Final Confirmat ion Test

Clear DTC if any.

Perform final confirmation test, refer to the next

page.

Is there a problem symptom, DTC or abnormal

condition?

Go to Step 6. End.

1. Customer Complaint Analysis (See Customer Problem Inspection Form).

Record details of the problem (failure, complaint) and how it occurred as described by the customer.

Use of an inspection form, refer to CUSTOM ER PR OB LEM I N SPEC TI ON FOR M (E XAM PLE ) , will enable the

collecting of information required for proper analysis and diagnosis.

2. Diagnostic Trouble Code (DTC) Check, Record and Clearance.

First, refer to 2.6 DTC CHECK in this Section, check the DTC. If a DTC exists, print or write down the DTC

and then c lear the mal function DTC(s), refer to 2.7 DTC CLEAR ANCE in this S ection. Ma lfunc tion DTC in di-

cates a malfunction in the system but it is not possible to know if the malfunction is occurring now or has

occurred in the past and that the normal condition has been restored. To confirm, check the symptom, refer to

Step 5 then recheck the DTC according to Step 6.

Diagnos in g a tr oub le b as ed on th e DTC in thi s s tep on ly, or failu r e to cl ear th e DT C in t his st ep , ma y resu lt i n

a faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.

3 and 4. Visual Inspection.

As a pre liminary step, be sure to perform a visual check of the items that support the prop er function of the

engine and the automatic transaxle, refer to 2.10 VISUAL INSPECTION in this Section.

5. Trouble Symptom Confirmation.

Check trouble symptoms based on the information obtained in S tep 1, Customer Complaint Analysis and Step

2, DTC Check.

Also, reconfirm the DTC according to the DTC CONFIRMATION PROCEDURE described in each DTC Flow

Table.

6 and 7. Rechecking and Record of DTC.

Refer to 2.6 DTC CHECK in this Section for checking procedure.

8. Automatic Transmission Basic Check and Trouble Diagnosis Table.

Perform a basic check of the A/T according to the flow table, refer to 2.11 AUTOMATIC TRANSAXLE

BASIC CHECK in this Section firs t. When the end of the flow table has be en reached, ch eck the parts of the

syst em susp ected as a possi ble cause of pro blems t hen refe r to 2.12 TR OUBLE DIAGNOSIS TABLE in this

Section. Based on the symptoms appearing on the vehicle (symptoms obtained through steps of customer

complaint analysis, trouble symptom confirmation and/or A/T basic check) repair or replace the faulty parts.

9. Diagnostic Trouble Code Flow Table (See each DTC Flow Table).

Based on the DTC indicated in Steps 6/7, refer to 2.8 DIAGNOSTIC TROUBLE CODE TABLE in this Section,

locate the cause of the trouble, name ly in a sensor, switch, wire harness, connecto r, actuator, TCM or other

part and repair or replace the faulty parts.

10. Check for Intermittent Problem.

Check the parts where an intermittent trouble is likely to occur (e.g. wire harness, connector, etc.), refer to

Section 0A, 1.7 ELECTRICAL CIRCUIT INSPECTION PROCEDURE, INTERMITTENT AND POOR

CONNECTION and the related circuit of the DTC recorded in Step 2.

11. Final Confirmation Test.

Confir m that the pr oble m sympto m has been corre cted and th at the vehic le is free fr om an y abn ormal c ondi-

tions. If the repaired item(s ) is related to the malfunctio n DTC, clear the DTC once and check to ensure that

no malfunction DTC is still indicated.

CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)

NOTE: The above form is a standard sample. It may be differ depending on requirements.

2.5 O/D OFF - LAMP CHECK

1. Turn the ignition switch ON.

2. Check that the O/D OFF lamp (1) lights for about 2 sec.

and then goes OFF.

If any faults are found, refer to

2.22 DIAGNOSTIC FLOW TABLE A-3 or

2.23 DIAGNOSTIC FLOW TABLE A-4 in this Section.

2.6 DIAGNOSTIC TROUBLE CODE (DTC) CHEC K

DTC CHECK USING TECH 2

1. Turn the ignition switch OFF.

2. Connect Tech 2 (A) to the data link connector (DLC) (1)

located in the un der side of the i ns trumen t panel o n th e

driver s side .

3. Turn the ignition switch ON.

4. Read the DTC according to the instructions displayed

on Tech 2 and note it. Refer to Tech 2 operator’s

manual for further details.

5. After completing the check, turn the ignition switch

OFF and disconnect Tech 2 from the data link

connector (DLC) (1).

DTC CHECK NOT USING TECH 2

1. Turn the ignition sw itch ON and make s ure that the O/

D OFF lamp (1) is OFF in the combination meter (with

O/D OFF switch OFF).

2. Turn the ignition switch OFF.

3. Remove the glove box (1) from the instrument panel.

4. Using a service wire, connect the diagnosis switch

terminal (1) and the ground terminal (2) of the

diagnosis connector No. 2 (3).

5. Turn the ignition switch OFF.

6. Read the DTC from the flashing pattern of the O/D

OFF lamp (1).

7. After completing the DTC check, turn the ignition

switch OFF and disconnect the service wire from the

diagnosis connector No. 2 (2).

2.7 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE

DTC CLEARANCE USING TECH 2

1. Turn the ignition switch OFF.

2. Connect Tech 2 (A) to data link connector (DLC) (1)

located In underside of instrument panel on the drivers

side.

3. Turn the ignition switch ON.

4. Clear the DTC according to the instructions displayed

on Tech 2. Refer to Tech 2 operator’s manual for

further details.

5. After comple ting the clearanc e, turn the ignitio n switch

OFF and disconnect Tech 2 from the data link

connector (DLC) (1).

DTC CLEARANCE NOT USING TECH 2

1. Remove the glove box (1) from the instrument panel.

2. Turn the ignition switch ON.

3. Using service wire, repeat connection and disconnec-

tion be tween diagnosis switch te rminal (1) and ground

terminal (2) of diagnosis connector No. 2 (3) 5 times

with about 1 second interval within 10 seconds.

4. Perform DTC CHECK and confirm that only DTC

No.12 (DTC of normal condition) is displayed, refer to

2.8 DTC TABLE in this Section. If not, Repeat Step 3

and recheck.

2.8 DIAGNOSTIC TROUBLE CODE (DTC) TABLE

NOTE:

• Type I of DTC: DTC code which can be checked by using Tech 2

• Type II of DTC: DTC code which can be checked by flashing “O/D OFF” lamp in combination

meter with diagnosis connector No. 2 diagnosis terminal connected to ground.

• *1: Application of O/D OFF lamp flashing by TCM when the malfunction is detected.

DTC NO. DETECTING ITEM DETECTING CONDITION

(DTC will set when detecting:)

“O/D OFF”

lamp flashing

Type I Type II

– 12 Normal (No malfunction

is detected.) ––

P0705 34 Transmission range sen-

sor circuit malfunction • No sensor signal is inputted.

• Multiple signals are inputted simulta-

neously

Applicable

P0710 36 Transmission fluid tem-

perature sensor circuit

malfunction

Sensor output voltage is too high (Circuit

open or shored to power circuit) Not applicab le

38 Sensor output voltage is too low (Circuit

shored to ground)

P0715 14 Input/Turbine speed sen-

sor circuit malfunction No sensor signal is detected although out-

put shaft speed sensor signal is detected. Applicable

P0720 31 Output speed sensor

(VSS) circuit malfunction No sensor signal is inputted although input

shaft speed sensor signal is inputted. Applicable

P0725 35 Engine speed input cir-

cuit malfunction No engine speed signal is inputted although

engine is running and engine temperature

senso r si gna l is in norma l cond iti on .

Applicable

P0743 25 Torque converter clutch

system electrical Voltage of TCC solenoid terminal is high

although TCM is commanding TCC sole-

noid to turn OFF.

Not applicab le

26 Voltage of TCC solenoid terminal is low

although TCM is commanding TCC sole-

noid to turn ON.

P0748 41 Pressure control sole-

noid electrical No electric flow is detected on solenoid cir-

cuit. Applicable

42 Too much electric flow is detected on pres-

sure control solenoid circuit.

DTC NO. DETECTING ITEM DE TECTING CONDITION

(DTC will set when detecting:)

“O/D OFF”

lamp flashing

Type I Type II

P0753 21 Shift solenoid-A (No.1)

electrical Voltage of shift solenoid terminal is high

although TCM is commanding shift solenoid

to turn OFF.

Applicable

22 Voltage of shift solenoid terminal is low

although TCM is commanding shift solenoid

to turn ON.

P0758 23 Shift solenoid-B (No.2)

electrical Voltage of shift solenoid terminal is high

although TCM is commanding shift solenoid

to turn OFF.

Applicable

24 Voltage of shift solenoid terminal is low

although TCM is commanding shift solenoid

to turn ON.

P0785 13 Timing solenoid • Voltage of timing solenoid terminal is

high although TCM is commanding tim-

ing solen oid to turn OFF.

• Volt age o f t i mi n g s ol e noid t e rm in al is lo w

although TCM is commanding timing

solenoid to turn ON.

Applicable

P1700 32 Throttle position signal

circuit malfunction Too short low signal of pulse signal from

ECM to TCM continues out of specification. Applicable

33 Too long low signal of pulse signal from

ECM to TCM continues out of specification.

P1702 52 Internal malfunction of

TCM Calc ulat io n of c ur rent dat a st or ed in T CM i s

not correct compared with pre-stored

checking data in TCM.

Applicable

P1705 51 Engine coolant tempera-

ture signal circuit mal-

function

• Too long high signal of pulse signal from

ECM to TCM continues out of specifica-

tion.

• Too long low signal of pulse signal from

ECM to TCM continues out of specifica-

tion.

• Too long or short low signal of pulse sig-

nal from ECM to TCM is detected in con-

tinuous 8 pulses.

Applicable

P1730 64 Engine torque signal cir-

cuit mal fun ct i on • Too short low signal of pulse signal from

ECM to TCM continues out of specifica-

tion.

• Too long low signal of pulse signal from

ECM to TCM continues out of specifica-

tion.

Applicable

P1895 27 Torque reduc ti on signal

circuit malfunction Voltage of torque reduction signal circuit

terminal is low although TCM does not

require ECM to reduce engine torque

Applicable

2.9 FAIL SAFE TABLE

This function is provid ed by the s afe mec hanis m that ass ures sa fe driv eabili ty even when the so lenoi d valv e,

sensor or its circuit fails.

The table below shows the fail safe function for each fail condition of solenoid, solenoid or its circuit.

DTC NO. TROUBLE AREA FAIL SAFE OPERATION

P0705 34 Transmission range sen-

sor or its circuit • Selected range is set as range shown below.

– In case of circuit open, selected range is assumed to be D

range.

– In case of circuit short (In case that 2 or more sensor sig-

nals are inputted), selected range is set in priority order

shown below.

D>2>L>R>N>P

• Lock-up function is inhibited to operate.

• Reverse control operation, which inhibit reverse driving at R

range while vehicle runs forward more than 11 km/h, is inhib-

ited.

• Learning control is inhibited.

P0710 36

38 Transmission fluid tem-

perature sensor or its cir-

cuit

• A/T fluid temperature is assumed to be 200°C.

• Lock-up function is inhibited to operate.

• Learning control is inhibited.

P0715 14 Input shaft speed sensor

or its circuit • Upshifting to O/D is inhibited.

• Lock-up function is inhibited to operate.

• Line pressure control at gear shifting is inhibited.

• Toque reducing request to ECM (torque reduction control) is

inhibited.

• Learning control is inhibited.

P0720 31 Output shaft speed sen-

sor or its circuit • Vehicle speed which is calculated by input shaft speed sen-

sor signal is used for gear shifting control instead of vehicle

speed calculated by output shaft speed sensor (VSS) signal.

• Upshifting to O/D is inhibited.

• Lock-up function is inhibited to operate.

• Reverse control operation, which inhibit reverse driving at R

range while vehicle runs forward more than 11 km/h, is inhib-

ited.

• Line pressure control at gear shifting is inhibited.

• Toque reducing request to ECM (torque reduction control) is

inhibited.

• Learning control is inhibited.

P0725 35 Engine speed signal cir-

cuit • Upshifting to O/D is inhibited.

• Line pressure control at gear shifting is inhibited.

• Toque reducing request to ECM (torque reduction control) is

inhibited.

• Lock-up function is inhibited to operate.

• Learning control is inhibited.

P0743 25

26 TCC solenoid valve or its

circuit • Lock-up function is inhibited to operate.

• When TCC solenoid circuit is shorted to power circuit and

vehicle speed is slower than 15 km/h, gear position is fixed in

1st gear for prevention of engine stall.

P0748 41

42 Pressure control sole-

noid va lve or its circuit • Power supply for all solenoid valves is cut.

• Gear position is fixed in 3rd gear.

• Toque reducing request to ECM (torque reduction control) is

inhibited.

• Up and down hill control is inhibited.

• Learning control is inhibited.

P0753 21

22 Shift solenoid-A valve or

its circuit

P0758 23

24 Shift solenoid-B valve or

its circuit

2.10 VISUAL INSPECTION

Visually check the following parts and systems.

P0785 13 Timing solenoid valve or

its circuit • Power supply for all solenoid valves is cut.

• Gear position is fixed in 3rd gear.

P1700 32

33 Throttle position signal

circuit • Throttle opening used for line pressure control is assumed to

be 100%.

• Throttle opening used for gear shifting control is assumed to

be 0%.

• Upshifting to O/D is inhibited.

• Lock-up function is inhibited to operate.

• Learning control is inhibited.

P1702 52 TCM • Power supply for all solenoid valves is cut.

• Gear position is fixed in 3rd gear.

P1705 51 Engine coolant tempera-

ture signal circuit After 15 minutes pass from detecting malfunction, engine cool-

ant temperature is assumed to be normal operating tempera-

ture, and controls of overdrive and lock-up is released from

inhibition.

P1730 64 Engine torque signal cir-

cuit • Engine torque is assumed to be that of last value before

detecting malfunction.

• Upshifting to O/D is inhibited.

• Line pressure control at gear shifting is inhibited.

• Toque reducing request to ECM (torque reduction control) is

inhibited.

• Learning control is inhibited.

P1895 27 Torque reduction signal

circuit Toque reducing request to ECM (torque reduction control) is

inhibited.

DTC NO. TROUBLE AREA FAIL SAFE OPERATION

INSPECTION ITEM REFERRING SE

CTION

• A/T fluid ----- level, leakage, colour Section 0B

• A/T fluid hoses ----- disconnection, looseness, deterioration

• Throttle cable ----- play (under warm engine), installation Section 6E1

• A/T select cable ----- installation

• Engine oil ----- level, leakage Section 0B

• Engine coolant ----- level, leakage Section 0B

• Engine mountings ----- play, looseness, damage Section 6A1

• Suspension ----- play, looseness Section 3

• Drive shafts ----- damage Section 4A

• Battery ----- indicator condition, corrosion of terminal

• Connectors of electric wire harness ----- disconnection, friction Section 6E1

• Fuses ----- burning Section 8

• Parts ----- installation, damage

• Bolts ----- looseness

• Other parts that can be checked visually

Also check the following items at engine start, if possible.

• “O/D OFF” lamp ----- Operation

• Malfunction indicator lamp ----- Operation Section 6E1

• Charge warning lamp ----- Operation Section 6H

• Engine oil pressure warning lamp ----- Operation Section 8 (Section 6A1 for pressure

check)

• Engine coolant temperature meter ----- Operation

• Other parts that can be checked visually

2.11 AUTOMATIC TRANSAXLE BASIC CHE CK

This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been

noted in visual inspection. Follow the flow table carefully.

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE DIAG-

NOSTIC FLOW TABLE preformed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Sect ion.

2Perform 2.13 ROAD TEST in this Section.

Is it OK? Go to Step 3. Proceed to TROUBLE-

SHOOTING in 2.13

ROAD TEST in this

Section.

3Perform 2.14 MANUAL ROAD TEST in this

Section.

Is it OK?

Go to Step 4. Proceed to TROUBLE-

SHOOTIN G 2.14

MANUAL ROAD TEST

in in this Section.

4Perform 2.15 ENGINE BRAKE TEST in this

Section.

Is it OK?

Go to Step 5. Proceed to TROUBLE-

SHOOTING in 2.15

ENGINE BRAKE TEST

in this Section.

5Perform 2.16 STALL TEST in this Section.

Is it OK? Go to Step 6. Proceed to TROUBLE-

SHOOTING in 2.16

STALL TEST in this

Section.

6Perform 2.17 TIME LAG TEST in this Section.

Is it OK? Go to Step 7. Proceed to TROUBLE-

SHOOTING in 2.17

TIME LAG TEST in this

Section.

7Perform 2.18 LINE PRESSURE TEST in this

Section.

Is it OK?

Go to Step 8. Proceed to TROUBLE-

SHOOTING in 2.18 LINE

PRESSU RE TEST in

this Section.

8Proceed to 2.12 TROUBLE DIAGNOSIS,

TABLE-1 in this Section.

Is trouble identified?

Repair or replace faulty

parts. Go to Step 9.

9Proceed to 2.12 TROUBLE DIAGNOSIS,

TABLE-2 in this Section.

Is trouble identified?

Repair or replace faulty

parts. Proceed to 2.12

TROUBLE D IAGN OS IS,

TABLE-3 in this Section.

2.12 TROUBLE DIAGNOSIS TABLE

TROUBLE DIAGNOSIS TABLE-1

Electri cal Repair

Condition Possible Cause Correction

Excessive shift

shock Shift solenoid valve-A and/or-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Pressure control solenoid valve circuit faulty

(Only when N→D or 3↔O/D shifting)

Timing solenoid valve circuit faulty

Output shaft speed sensor (VSS) circuit faulty

Input shaft speed senso r cir cuit faul ty

Transmission fluid temperature sensor circuit

faulty

Throttle position signal circuit faulty

Engine speed signal circuit faulty

Engine torque signal circuit faulty

Torque reduction request signal circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

Crank position sensor circuit faulty

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

(When O/D↔3 shifting and any upshifting)

Improper learning control of TCM Initialise learning control and perform

learning, refer to 3.12 TRANSMISSION

CONTROL MODULE (TCM), LEARNING

CONTROL INITIALIS AT ION and BRIEF

LEARNING in this Section.

No gear shift as

3rd gear Shift solenoid valve-A and/or-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Pressure control solenoid valve circuit faulty

Timing solenoid valve circuit faulty

TCM Substitute a known-good TCM and

recheck.

Poor 1→2 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Output shaft speed sensor (VSS) circuit faulty

Transmission range sensor circuit faulty

Throttle position signal circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Poor 2 →3 shift

Shift solenoid valve-A circuit faulty

Inspect circuit for open, short and in ter-

mitten t. If NG, repair.

Output shaft speed sensor (VSS) circuit

faulty

Tra ns m is s io n ra ng e sen s or ci rc ui t fau lt y

Throttle position signal circ uit faulty

Throttle position sensor circ uit faulty

Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Poor 3→O/D

shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Pressure control solenoid valve circuit faulty

Timing solenoid valve circuit faulty

Output shaft speed sensor (VSS) circuit faulty

Input shaft speed senso r cir cuit faul ty

Transmission range sensor circuit faulty

Transmission fluid temperature sensor circuit

faulty

Throttle position signal circuit faulty

Engine coolant temperature signal circuit

faulty

Engine speed signal circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

Engine coolant temperature sensor circuit

faulty

Crank position sensor circuit faulty

O/D off switch circuit faulty Refer to 2.20 DIAGNOSTIC FLOW TABLE

A-1: NO GEAR SHIFT TO O/D in this

Section.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Poor O/D→3

shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Pressure control solenoid valve circuit faulty

Timing solenoid valve circuit faulty

Output shaft speed sensor (VSS) circuit faulty

Input shaft speed senso r cir cuit faul ty

Throttle position signal circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent referring to Section 6. If NG, repair.

O/D off switch circuit faulty Refer to 2.20 DIAGNOSTIC FLOW TABLE

A-1: NO GEA R SHI F T TO O/Din this

section.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Condition Possible Cause Correction

Poor 3→2 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Output shaft speed sensor (VSS) circuit faulty

Throttle position signal circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Poor 2→1 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Output shaft speed sensor (VSS) circuit faulty

Throttle position signal circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Incorrect gear

shift point Output shaft speed sensor (VSS) circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Pressure control solenoid valve circuit faulty

Throttle position signal circuit faulty

Pressure control solenoid valve circuit faulty

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GENERAL

INFORMATION AND DIAGNOSIS. If NG,

repair.

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Condition Possible Cause Correction

Non operate

TCC (lock-up )

system

TCC solenoid valve-B circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

Shift solenoid valve-A and/or-B circuit faulty

Pressure control solenoid valve circuit faulty

Output shaft speed sensor (VSS) circuit faulty

Input shaft speed senso r cir cuit faul ty

Transmission range sensor circuit faulty

Transmission fluid temperature sensor circuit

faulty

Engine coolant temperature signal circuit

faulty

Throttle position signal circuit faulty

Brake light switch circuit faulty Refer to 2.21 DIAGNOSTIC FLOW TABLE

A-2: NO LOCK UP OCCU RS in this

section.

Throttle position sensor circuit faulty Inspect circuit for open, short and intermit-

tent, refer to Section 6 ENGINE GEN-

ERAL INFORMATION AND DIAGNOSIS.

If NG, repair.

Engine coolant temperature sensor circuit

faulty

TCM Substitute a known-good TCM and

recheck.

ECM Substitute a known-good ECM and

recheck.

Higher or lower

stall speed Pressure control solenoid valve circuit faulty Inspect circuit for open, short and intermit-

tent. If NG, repair.

TCM Substitute a known-good TCM and

recheck.

Excessive

N→D or N→R

time lag

Pressure control solenoid valve circuit

faulty

Inspect circuit for open, short and intermit-

tent. if NG, repair

Transmission fluid temperature sensor cir-

cuit faulty

TCM Substitute a known-good TCM and

recheck.

Higher or lower

line pressure

Pressure control solenoid valve circuit

faulty Inspect circuit for open, short and inter-

mitten t. If NG, repair.

TCM Substitute a known-good TCM and

recheck.

Condition Possible Cause Correction

TROUBLE DIAGNOSIS TABLE-2

On-vehicle Repair

Condition Possible Cause Correction

Unable to run in all

range Faulty valve body component Replace valve body assembly

Excessive shift

shock Engine abnormal condition Inspect and repair engine

Malfunction of shift solenoid valve-A and/or-B Inspect. If NG, replace

Malfunction of output shaft speed sensor (VSS)

Malfunction of input shaft speed sensor

Malfunction of transmission range sensor

Malfunction of Transmission fluid temperature sen-

sor

(Only when N→D or 3↔O/D shifting)

Malfunction of timing solenoid valve

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve

body assembly.

(Except N→D or N→R shifting)

Malfunction of brake light switch Inspect, refer to Section 5

BRAKES. If NG, replace.

Malfunction of crank position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Malfunction of throttle position sensor

Faulty valve body component Replace valve body assembly.

Poor 1→2 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of output shaft speed sensor (VSS)

Malfunction of transmission range sensor

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Faulty valve body component Replace valve body assembly.

Poor 2→3 shift Malfunction of shift solenoid valve-A Inspect. If NG, replace.

Malfunction of output shaft speed sensor (VSS)

Malfunction of transmission range sensor

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Faulty valve body component Replace valve body assembly.

Poor 3→O/D shift Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of timing solenoid valve

Malfunction of output shaft speed sensor (VSS)

Malfunction of input shaft speed sensor

Malfunction of transmission range sensor

Malfunction of Transmission fluid temperature sen-

sor

Malfunction of O/D off switch

Malfunction of engine coolant temperature sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Malfunction of throttle position sensor

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve

body assembly.

Faulty valve body component Replace valve body assembly.

Poor O/D→3 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of timing solenoid valve

Malfunction of output shaft speed sensor (VSS)

Malfunction of input shaft speed sensor

Malfunction of O/D off switch

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve

body assembly.

Faulty valve body component Replace valve body assembly.

Poor 3→2 shift Malfunction of shift solenoid valve-A Inspect. If NG, replace.

Malfunction of output shaft speed sensor (VSS)

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Faulty valve body component Replace valve body assembly.

Poor 2→1 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of output shaft speed sensor (VSS)

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Faulty valve body component Replace valve body assembly.

Incorrect shift point Engine abnormal condition Inspect and repair engine

Malfunction of output shaft speed sensor (VSS) Inspect. If NG, replace.

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Non operate TCC

(lock-up) system Malfunction of TCC solenoid valve Inspect. If NG, replace.

Malfunction of shaft solenoid valve-A and/or-B

Malfunction of output shaft speed sensor (VSS)

Malfunction of input shaft speed sensor

Malfunction of transmission range sensor

Malfunction of transmission fluid temperature sensor

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve

body assembly.

Malfunction of brake light switch Inspect, refer to Section 5

BRAKES. If NG, replace.

Malfunction of throttle position sensor Inspect, refer to Section 6E1

ENGINE EMISSION AND

CONTROL SYSTEM. If NG,

replace.

Malfunction of engine coolant temperature sensor

Malfunction of brake light switch Inspect, refer to Section 5

BRAKES. If NG, replace.

Faulty valve body component Replace valve body assembly.

Excessive N→D or

N→R time lag Malfunction of transmission fluid temperature sensor Inspect. If NG, replace.

Pressure control solenoid valve circuit faulty Inspect. If NG, replace valve

body assembly.

Clogged oil strainer Replace.

Faulty valve body component Replace valve body assembly.

Condition Possible Cause Correction

TROUBLE DIAGNOSIS TABLE-3

Off-veh icle Repair

Condition Possible Cause Correction

Unable to run in all range Faulty oil pump Inspect. If NG, replace.

Seized or broken planetary gear

Faulty one-way clutch No.2

Damaged drive plate

Faulty forward clutch

Faulty reverse clutch

Faulty 1st and reverse brake

Faulty torque converter Replace

Excessive N→D shift shock Faulty forward clutch Inspect. If NG, replace.

Excessive N→R shift shock Faulty reverse clutch Inspect. If NG, replace.

Faulty 1st and reverse brake

Poor 1→2 shift, excessive shock or

slippage Faulty 2nd brake Inspect. If NG, replace.

Faulty one-way clutch No.1

Poor 2→3 shift, excessive shock or

slippage Faulty direct clutch Inspect. If NG, replace.

Poor 3↔O/D shift, excessive shock

or slippage Faulty forward clutch Inspect. If NG, replace.

Faulty O/D and 2nd coast brake

Poor 3→2 shift, excessive shock or

slippage Faulty direct clutch Inspect. If NG, replace.

Faulty one-way clutch No.1

Poor 2→1 shift, excessive shock or

slippage Faulty 2nd brake Inspect. If NG, replace.

Faulty one-way clutch No.2

Non operate TCC (lock-up) system Faulty torque converter Replace.

Excessive N→D time lag Faulty oil pump Inspect. If NG, replace.

Faulty forward clutch

Faulty one-way clutch No.2

Leakage from D range fluid pressure cir-

cuit Overhaul or replace valve

body assembly.

Excessive N→R time lag Faulty oil pump Inspect. If NG, replace.

Faulty reverse clutch

Faulty 1st and reverse brake

Leakage from R range fluid pressure cir-

cuit Overhaul or replace valve

body assembly.

Poor engine brake in downshift to 2

range Faulty O/D and 2nd coast brake Inspect. If NG, replace.

Poor engine brake in downshift to L

range Faulty 1st and reverse brake. Inspect. If NG, replace.

2.13 RO A D TEST

This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehi-

cle on a level road.

WARNING:

• Carry out this test in safe area.

• Test requires 2 persons, a driver and a tester.

1. Warm up the engine.

2. With the engine running at idle, shift selector lever to D range.

3. Raise the vehicle speed by depressing the accelerator pedal gradually.

4. Wh ile driv ing in D range, check that the ge ar shift and l ock-up oc cur pro perly a s shown in GEAR S HIFT

DIAGRAM and LOCK-UP DIAGRAM. (Refer to 1.5 TRANSMISSION CONTROL MODULE (TCM)

AUTOMATIC GEAR SHIFT DIAGRAM in this Section.)

TROUBLESHOOTING

Condition Possible Cause Correction

Unable to run in all

range Faulty valve body component Replace valve body assembly

Faulty oil pump Inspect. If NG, replace.

Seized or broken planetary gear

Faulty one-way clutch No.2

Faulty forward clutch

Faulty reverse clutch

Faulty 1st and reverse brake

Damaged drive plate

Faulty torque converter Replace.

No gear shift in 3rd

gear Malfunction of shift solenoid valve-A and/or-B Inspect. If NG, replace.

Malfunction of timing solenoid valve

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve body

assembly.

1→2 upshift fails to

occur Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of output shaft speed sensor

(VSS)

Malfunction of throttle position sensor

Malfunction of transmission range sensor

Faulty valve body component Replace valve body assembly

Faulty 2nd/4th brake Inspect. If NG, replace.

Faulty one-way clutch No.1

2→3 upshift fails to

occur Malfunction of shift solenoid valve-A Inspect. If NG, replace.

Malfunction of output shaft speed sensor

(VSS)

Malfunction of throttle position sensor

Malfunction of transmission range sensor

Faulty valve body component Replace valve body assembly.

Faulty direct clutch Inspect. If NG, replace.

3→O/D upshift fails to

occur Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of O/D off switch

Malfunction of engine coolant temperature

sensor

Malfunction of output shaft speed sensor

(VSS)

Malfunction of input shaft speed sensor

Malfunction of throttle position sensor

Malfunction of transmission range sensor

Malfunction of crankshaft position sensor

Malfunction of timing solenoid valve

Malfunction of transm ission fluid temperature

sensor

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Faulty O/D and 2nd coast brake Inspect. If NG, replace.

O/D→3 downshift fails

to occur Malfunction of shift solenoid valve-A Inspect. If NG, replace.

Malfunction of O/D off switch

Malfunction of output shaft speed sensor

(VSS)

Malfunction of input shaft speed sensor

Malfunction of throttle position sensor

Malfunction of timing solenoid valve

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Faulty forward clutch Inspect. If NG, replace.

3→2 downshift fails to

occur Malfunction of shift solenoid valve-A Inspect. If NG, replace.

Malfunction of output shaft speed sensor

(VSS)

Malfunction of throttle position sensor

Faulty valve body component Replace valve body assembly.

Faulty one-way clutch No.1 Inspect. If NG, replace.

2→1 downshift fails to

occur Malfunction of shift solenoid valve-B Inspect. If NG, replace.

Malfunction of output shaft speed sensor

(VSS)

Malfunction of throttle position sensor

Faulty valve body component Replace valve body assembly.

Faulty one-way clutch No.2 Inspect. If NG, replace.

Gear shift point is incor-

rect Abnorm al engine co nditio n Inspect and re pair engine .

Malfunction of output shaft speed sensor

(VSS) Inspect. If NG, replace.

Malfunction of throttle position sensor

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve body

assembly.

Condition Possible Cause Correction

2.14 MANUAL ROAD TEST

This test checks the gears being used in L, 2 or D range

when driven with the gear shift control system not operat-

ing. Test drive the vehicle on a level road.

NOTE: Before this test, check the diagnostic trouble code

(DTC).

1. With select lever in P, start engine and warm it up.

2. After warmi ng up engi ne, turn ignit ion swit ch OFF and

disconnect valve body harness connector (1).

3. With select lever in L range, start the vehicle and check

that 3rd gear is being used, refer to the table below.

Vehicle speed per 1000 rpm in engine speed (V1000

table, reference).

4. With the vehicle running, shift the select lever to 2 range and check that 3rd gear is being used.

5. With the vehicle running, shift the select lever to D range and check that 3rd gear is being used.

6. When the checks are completed, stop the vehicle, turn the ignition switch OFF and connect the valve

body harness connector.

7. Clear the DTC.

TROUBLESHOOTING

TCC (lock-up ) functi on

does not operate Malfunction of TCC solenoid valve Inspect. If NG, replace.

Malfunction of shift solenoid valve-A and/or-B

Malfunction of brake light switch

Malfunction of engine coolant temperature

sensor

Malfunction of output shaft speed sensor

(VSS)

Malfunction of input shaft speed sensor

Malfunction of throttle position sensor

Malfunction of transmission range sensor

Malfunction of transm ission fluid temperature

sensor

Malfunction of pressure control solenoid valve Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Faulty torque converter Replace.

Condition Possible Cause Correction

Gear position Vehicle speed

1st 8.9 km/h

2nd 16.3 km/h

3rd 25.5 km/h

4th (O/D) 36.6 km/h

Reverse 11.1 km/h

Condition Possible Cause Correct ion

Operated gear is not

correct Faulty valve body component Replace valve body assembly.

Faulty clutch or brake Inspect clutch and brake. If any

parts are faulty, replace them.

2.15 ENGINE BRAKE TEST

WARNING: Before test, ensure that the area behind the vehicle is clear .

1. While driving vehicle in 3rd gear of D range, shift select lever down to 2 range and check that engine

brake operates.

2. As in Step 1, check th e engine bra ke for op eration when the select lever is shifted down to L range and

check that engine brake operates.

3. Engine brake should operate in above test.

TROUBLESHOOTING

2.16 STALL TEST

This test checks the overall performance of the automatic transaxle and the engine by measuring the stall

speed at D and R ranges. Be sure to perform this test only when the transaxle fluid is at normal operating tem-

perature and its level is between FULL and LOW marks.

CAUTION:

• Do not run the engine at stall for more than 5 seconds continuously, or fluid te mperature may rise

excessively.

• After performing the stall test, be sure to leave the engine running at idle for more than 1 minute

before performing another stall test.

1. Apply parking brake and block wheels.

2. Install tach ome ter.

3. Start engine with select lever shifted to P range.

4. Depress the brake pedal fully.

5. Shift th e select lever to D range and depress the accelerator pedal f ully while watching the tachometer.

Note the engine rpm as soon as the rpm becomes constant (stall speed).

6. Release the accelerator pedal immediately after stall speed has been checked.

7. As in Step 6/7, check and note stall speed in R range.

8. Stall speed should be within following specification.

Conditi on Possible Caus e Correctio n

Failure to operate

when shifted down to

2 range

Faulty valve body component Replace valve body assembly.

Faulty O/D and 2nd coast brake Inspect. If NG, replace.

Failure to operate

when shifted down to

L range

Faulty valve body component Replace valve body assembly.

Faulty 1st and reverse brake Inspect. If NG, replace.

ENGINE STALL SPEED STANDARD 2200 - 2600 RPM

TROUBLESHOOTING

2.17 TIME LAG TEST

This test checks the condition of the clutch, brake and fluid pressure. “Time lag” means the time

elapsed since the selector lever is shifted with engine idlin g until shock is felt.

1. With chocks placed in front and behind front and rear wheels, depress the brake pedal.

2. Start the engine.

3. With a stop watch ready, shift the select le ve r from N to D range and mea sure the tim e from tha t mome nt

until shock is felt.

4. As in Step 3, measure the time lag by shifting the select lever from N to R range.

NOTE:

• When repeating this test, be sure to wait at least one minute after the select lever is returned to N range.

• The engine should be fully warmed for this test.

• Repeat the test 3 times and take an average of those times for final time lag data.

Condition Possible Cause Correction

Lower than standard

level in both D and R

range

Engine output torque failure Inspect and repair engine.

Faulty one-way clutch of torque converter Replace torque converter.

Higher than standard

level in D range Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Slippery forward clutch Inspect. If NG, replace.

Faulty one-way clutch No.2

Leakage from D range fluid pressure circuit Overhaul or replace valve body

assembly.

Higher than standard

level in R range Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Slippery reverse clutch Inspect. If NG, replace.

Slippery 1st and reverse brake

Leakage from R range fluid pressure circuit Overhaul or replace valve body

assembly.

Higher than standard

level in both D and R

range

Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Clogged oil strainer Replace.

Faulty oil pump Inspect. If NG, replace.

Leakage from both D and R range fluid pres-

sure ci rcuit Overhaul or replace valve body

assembly.

GEAR SHIFTING TIME LAGN

→

R LESS THAN 0.7 SEC

LESS THAN 1.2 SEC

TROUBLESHOOTING

2.18 LINE PRESSURE TEST

The purpose of this test is to check the operating conditions

of each part by measuring the fluid pressure in the fluid

pressure line.

Line pressure test requires the following conditions.

• Automatic fluid is at normal operating temperatu re (70

– 80°C).

• Fluid is replenished to proper level (between FULL and

LOW on dipstick).

• Air conditioner switch is turned OFF.

1. Apply the parking brake securely and place chocks

against wheels.

2. Remove the fluid pressure check hole plug bolt.

3. Attach oil pressure gauge, special tool 09925-37811-

001 (A) to the fluid pressure check hole in the transaxle

case.

CAUTION: After attaching the oil pressure gauge,

check that there are no fluid leaks.

4. Depress the foo t brake fully, run the engin e at idle and

stall then check the fluid pressure in D or R range.

CAUTION:

• Do not run t he engine a t stall speed for mo re t han 5

seconds.

• After performing the line pressure test, leave the

engine running at idle for more than one minute

before performing another line pressure test.

Condition Possible Cause Correction

N → D time lag

exceeds specification Malfunction of transmission fluid temperature

sensor Inspect. If NG, replace.

Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Clogged oil strainer Replace.

Faulty oil pump Inspect. If NG, replace.

Faulty forward clutch

Faulty one-way clutch No.2

Leakage from “D” range fluid pressure circuit Overhaul or replace valve body

assembly.

N → R time lag

exceeds specification Malfunction of transmission fluid temperature

sensor Inspect. If NG, replace.

Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Clogged oil strainer Replace.

Faulty oil pump Inspect. If NG, replace.

Faulty reverse clutch

Faulty 1st and reverse brake

Leakage from “R” range fluid pressure circuit Overhaul or replace valve body

assembly.

AUTOMATIC TRANSMISSION LINE PRESSURE

TROUBLESHOOTING

2.19 P RANGE TEST

1. Stop the vehicle on a slope of 5 degrees or more, shift the select lever to P range while applying the

parking brake.

2. Stop the engine, depress the brake pedal and release the parking brake.

3. Release the brake pedal gradually and check that the vehicle remains stationary.

4. Depress the brake pedal and shift the select lever to N range.

5. Release the brake pedal gradually and check that the vehicle moves.

WARNING: Before test, make sure that the area around the vehicle is clear.

TROUBLESHOOTING

2.20 DIAGNOSTIC FLOW TABLE A-1: NO GEAR SHIFT TO O/D

SYSTEM DESCRIPTION

TCM does not shift to O/D gear under any of the following conditions.

• O/D off switch is turned ON (O/D OFF lamp lights)

• Engine coolant temperature is less than 50°C

• A/T fluid temperature is less than 20°C

• Input shaft speed sensor or its circuit is faulty (P0715)

• Output shaft speed sensor (VSS) or its circuit is faulty(P0720)

• Engine speed signal circuit is faulty (P0725)

• Pressure control solenoid valve or its circuit is faulty (P0748)

• Engine torque sign al ci rcuit is faul ty (P17 30)

D range R range

At idle speed 3.8 – 4.2 kg/cm

6.0 – 7.0 kg/cm

At stall speed 10.9 – 12.1 kg/cm

16.7 – 19.3 kg/cm

Condition Possible Cause Correction

Higher than standard

level in each range Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Lower than standard

level in each range Malfunction of pressure control solenoid valve

(Low line press ure) Inspect. If NG, replace valve body

assembly.

Faulty valve body component Replace valve body assembly.

Clogged oil strainer Replace.

Faulty oil pump Inspect. If NG, replace.

Leakage from both “D” and “R” range fluid

pressure circuit Overhaul or replace valve body

assembly.

Lower than standard

level only in D range Leakage from “D” range fluid pressure circuit Overhaul or replace valve body

assembly.

Lower than standard

level only in R range Leakage from “R” range fluid pressure circuit Overhaul or replace valve body

assembly.

Condition Possible Cause Correction

Vehicle moves at P range or remains

stationary at N range Defective parking lock pawl or spring Inspect. If NG, repair.

TROUBLESHOOTING

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme

caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

Step Action Yes No

Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE in this section

performed?

Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

Check DTC.

Is DTC P0715, P0720, P0725, P0748 or

P1730 detected?

Perform DTC Flow table

to repair and retry. Go to Step 3.

Perform runni ng test under the following

conditions and measure the voltage

between terminal C44-4 of TCM connector

and ground, terminal C44-3 of TCM connec-

tor and ground .

• O/D off switch is turne d OFF

• Eng ine coolan t tempe rature i s in norm al

operating temperat ure

• Sel ector lever is in D range

• Drive the vehicle in 4th gear condition,

refer to AUTOMATIC GEAR SHIFT

DIAGRAM in 1.5 TCM in this Section.

Do results satisfy the value as follows?

Voltage between terminal C44-4 of TCM

conn ec tor and grou nd: 0 – 1 V

Voltage between terminal C44-3 of TCM

conn ec t or and grou n d: 9 – 14 V

Fau lt y sh i ft sole no id

valve, circuit or tran-

saxle.

BRN circuit shorted to

power circ uit o r open, or

BLK/YEL circuit shorted

to ground. If wire is OK,

go to Step 4.

O/D off switch signal inspection.

With ignition switch ON, check voltage

between terminal G99-3 of TCM connector

and ground.

O/D off switch OFF: 8 – 14 V

O/D off switch ON: 0 – 1 V

Substitute a known-

good TCM and recheck. Faulty O/D off switch or

its circ ui t.

If OK, substitute a

known good TCM and

recheck.

2.21 DIAGNOSTIC FLOW TABLE A-2: NO LOCK-UP OCCURS

SYSTEM DESCRIPTION

The TCM turns the TCC solenoid OFF under any of the following conditions:

• Brake light switch is turned ON (Brake pedal is depressed)

• Engine coolant temperature is less than 60°C

• Throttle opening is as much as 0%

• Transmission range sensor or its circuit is faulty (P0705)

• Transmission fluid temperature sensor or its circuit is faulty (P0710)

• Input shaft speed sensor or its circuit is faulty (P0715)

• Output shaft speed sensor (VSS) or its circuit is faulty (P0720)

• TCC (lock-up) solenoid valve or its circuit is faulty (P0743)

• Pressure control solenoid valve or its circuit is faulty (P0748)

• Shift solenoid valve-A or its circuit is faulty (P0753)

• Shift solenoid valve-B or its circuit is faulty (P0758)

• Throttle position signal circuit is faulty (P1700)

TROUBLESHOOTING

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme

caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE in this Section

performed?

Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2Check DTC.

Is DTC P0705, P0710, P0715, P0720, P0743,

P0748, P0753, P0758 or P1700 detected?

Perform DTC Flow Table

to repair and retry. Go to Step 3.

3• Perform running test under the following

condi tions and c heck vol tage between te r-

minal C44-12 of TCM connector and

ground.

• Engine coolant temperature is in normal

operating temperature.

• O/D OFF switch is turned OFF.

• Selector lever is in D range.

• Brake pedal is released.

• Drive vehicle with 4th gear and TCC ON

condition, refer to AUTOMATIC GEAR

SHIFT DIAGRAM in 1.5 TCM in this Sec-

tion.

Is terminal voltage about 9 – 14 V?

Faulty TCC solenoid

valve, circuit or transaxle. GRN/WHT circuit shorted

to ground. If wire is OK,

go to Step 4.

4Brake light switch signal inspection

With ignition switch ON, check voltage

between terminal C44-16 of TCM connector

and ground.

Brake pedal is released: 0 – 1 V

Brake pedal is depressed: 8 – 14 V

Is result a s sp ecif i ed?

Substitute a known - good

TCM and rech ec k. Mis-adj us ted brak e light

switch, faulty brake light

switch or its circuit.

If OK, substitute a know-

good TCM and recheck.

2.22 DIAGNOSTIC FLOW TABLE A-3: O/D OFF LAMP CIRCUIT CHECK

(O/D OFF LAMP LIGHTS STEADILY )

WIRING DIAGRAM

Legend

CIRCUIT DESCRIPTION

Operation (ON/OFF) of the O/D OFF lamp is controlled by the transmission control module (TCM).

When the ignition switch is turned ON and a malfunction is not detected, the TCM turns the O/DOFF lamp ON

for only 2 seconds to check the bulb then turns it OFF.

When the i gnitio n switc h is turne d ON , regardl ess of wether the engi ne is runn ing or not and a malfunc tion is

detected, the O/D OFF lamp is flashed by the TCM while the malfunction is detected. This warns the driver of

a problem.

TROUBLESHOOTING

1. TCM 3. To ignition switch 5. Terminal arrangement of

2. O/D OF” lamp 4. O/D off switch TCM connector

3. To ign iti on swit ch (vie wed fro m harnes s si de)

Step Action Yes No

1 Check O/D off switch status.

Press O/ D OF F swi tc h butt on .

Does O/D OFF lamp light steadily?

Go to Step 2. System is OK

2 Check O/D OFF lamp circuit for short.

Turn ignition switch OFF and disconnect TCM

connectors.

Turn ignition switch ON.

Does O/D OFF lamp light steadily yet?

RED/BLK circuit shorted

to ground. Go to Step 3.

3 Check O/D OFF switch circuit.

Turn ignition switch OFF.

Check continuity between terminal G99-3 of

disconnected harness side connector and

ground.

Is continui ty indicate d?

Go to step 4. Substitute a known-good

TCM and recheck.

4 Check O/D OFF switch for operation.

Disconnect O/D off switch connector.

Check continuity between terminals under

each condition below.(See fig.)

O/D OFF switch is released: No continuity

O/D OFF switch is held in: Continuity

Is check result satisfactory?

RED/BLU circuit shorted

to ground. Replace O/D off switch.

Figure for Ste p 2 and Step 4 showing O/D OFF switch con-

nector (1).

2.23 DIAGNOSTIC FLOW TABLE A-4: O/D OFF LAMP CIRCUIT CHE CK

(O/D OFF LAMP DOES NOT LIGHT AT ALL)

WIRING DIAGRAM

Legend

1. TCM 3. To ignition switch 5. Terminal arrangement of

TCM connector

(viewed from harness side)

2. “O/D OFF” lamp 4. O/D off switch

CIRCUIT DESCRIPTION

The operation (ON/OFF) of the O/D OFF lamp is controlled by the transmission control module (TCM).

When the ignition switch is turned ON and a malfunction is not detected, the TCM turns the O/D OFF lamp ON

for only 2 seconds to check bulb then turns it OFF.

When the ig nition switch in turned ON , regardl ess of wether the engine is run ning or not and a mal functi on is

detected, the O/D OFF lamp is flashed by the TCM while the malfunction is detected. This warns the driver of

a problem.

TROUBLESHOOTING

2.24 DIAGNOSTIC FLOW TABLE A-5: TCM POWER AND GR OU ND CIRCUIT CHECK

WIRING DIAGRAM

Legend

Step Action Yes No

1Check O/D OFF lamp circuit.

Turn ignition switch OFF and disconnect TCM

connectors.

Using service wire, connect terminal G99-10 of

disconnected harness side TCM connector

and ground.

Turn ignition switch ON.

Does O/D OFF lamp light?

Poor terminal G99-10

connection.

If OK, substitute a known-

good TCM and recheck.

RED/BLK circuit open or

bulb burned out.

1. TCM 3. Ignition switch 4. Terminal arrangement of

TCM connector

(viewed from harness side)

2. A/T relay

TROUBLESHOOTING

2.25 DTC P0705/DTC NO.34 TRANSMISS ION RA NGE SENSOR

CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

Step Action Yes No

1 Check TCM Power Circuit.

Disconnect TCM connector with ignition switch

OFF.

Check for proper connection to TCM at C44-20

terminal.

If OK, turn ignition switch ON and check volt-

age at terminal C44-20 of disconnected TCM

connector.

Is it 10 – 14 V?

Go to Step 3. Go to Step 2.

2 Check A/T Relay Operation.

Check A/T relay operation, refer to 3.13 A/T

RELAY, INSPECTION in this Section.

Is check result satisfactory?

YEL/BLK, YEL/BLU.

BLK/W HT or BLK circuit

for power supply open.

Replace A/T relay.

Check TCM Ground Circuit.

1) Turn igniti on switch OFF.

2) With TCM connectors disconnected,

check for proper c onnection to TCM at

C44-15/C44-19 terminal.

3) If OK, check resistance between C44-

15/C44-19 terminal of disconnected

TCM connector and body ground.

Is continuity indicated?

TCM power and ground

circuits are in good con-

dition.

BLK circuit for TCM

ground open.

21 20

C44 G99

ORN

RED

GRN

GRN/ORN

GRN/YEL

IG11

RED/BLK

BLU/WHT

G99-2

G99-1

G99-9

G99-8

G99-21

G99-20

1. TCM 3. Backup lamp 4. T erminal arrangement of TCM

connector (viewed from har-

ness side)

2. Transmission range sensor

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme

caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory and start the engine.

3. Shift the selector lever to each of L, 2, D, N, R and P ranges for 20 seconds each.

4. Start the vehicle and increase the vehicle speed to about 40 km/h in D range.

5. Keep driving at about 40 km/h vehicle speed for 40 seconds.

6. Release the accelerator pedal, decrease the vehicle speed and stop the vehicle.

7. Check the DTC.

TROUBLESHOOTING

DTC DETECTING CONDITION TROUBLE AREA

• Transmission range switch signal (P, R, N, D, 2, or L)

is not inputted for more than 32 seconds when vehicle

speed is faster than 30 km/h and engine speed is

faster than 1500 rpm.

• Two or more signals are inputted simultaneously for

12 seconds.

• Transmission range sensor (switch) malad-

justed.

• T ransmission range sensor (switch) or its circuit

malfunction.

•TCM

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2Do you have Tech 2? Go to Step 3. Go to Step 4.

3Check Transmission range sensor(switch) cir-

cuit for operation.

Check by using Tech 2:

Connect Tech 2 to DLC with ignition switch

OFF.

Turn ignition switch ON and check transmis-

sion range signal (P, R, N, D, 2 or L) on display

when shifting select lever to each range.

Is applicable range indicated?

Are check results satisfactory?

Intermittent trouble.

Check for intermittent

refer to Section 0A,

1.7 ELECTRICA L

CIRCUIT INSPECTION

PROCEDURE,

INTERMITTENT AND

POOR CONNECTION.

Go to Step 5.

4Check Transmission range sensor(switch) cir-

cuit for operation.

Check by not using Tech 2:

Turn ignition switch ON.

Check voltage at terminals G99-1, G99-2,

G99-8, G99-9, G99-20 and G99-21 respec-

tively with select lever shifted to each range.

Taking terminal G99-21 as an example, is bat-

tery voltage indicated only when select lever is

shifted to 2 range and 0 V for other ranges as

shown in table below?

Chec k voltag e at othe r terminal s likewis e, ref er

to the figure.

Are check results satisfactory?

Intermittent trouble.

Check for intermittent

refer to Section 0A,

1.7 ELECTRICA L

CIRCUIT INSPECTION

PROCEDURE,

INTERMITTENT AND

POOR CONNECTION.

Go to Step 5.

Table for Step 4

2.26 DTC P0710/DTC NO.36 OR 38 TRANSMISSION FLUID TEMPERATURE

SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

5Check select cable for adjustment, refer to

3.3 SELECT CABLE, ADJUSTMENT in this

Section.

Is it adjusted correctly?

Go to Step 6. Adjust.

6Check transmission range sensor for installa-

tion position.

Shift select lever to N range.

Check that N reference line on sensor and

needle direction shaped on lock washer are

aligned.

Are they aligned?

Go to Step 7. Adjust.

7Check Transmission range sensor (switch),

refer to 3.4 TRANSMISSION RANGE

SENSOR (SHIFT SWITCH) in this Section.

Are check results satisfactory?

RED/BLK, ORN, RED,

GRN/ORN, GRN, GRN/

YEL or BLU/WHT circuit

open or short.

If wires and connections

are OK, substitute a

know-good TCM and

recheck.

Replace Transmission

range sensor.

Step Action Yes No

Terminal

G99-2 G99-1 G99-9 G99-8 G99-21 G99-20

Select lever

position P8 – 14 V0 V0 V0 V0 V0 V

R0 V8 – 14 V0 V0 V0 V0 V

N 0 V 0 V 8 – 14 V 0 V 0 V 0 V

D 0 V 0 V 0 V 8 – 14 V 0 V 0 V

2 0 V 0 V 0 V 0 V 8 – 14 V 0 V

L0 V0 V0 V0 V0 V8 – 14 V

C44 G99

GRN

C44-5

C44-14

BLU/RED

1. TCM 3. A/T 5. Terminal arrangement of TCM

connector (viewed from

harness side)

2. Transmission fluid tempera-

ture sensor 4. Valve body connector

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory and start the engine.

3. Shift the selector lever to D range and drive the vehicle for about 20 minutes.

4. Stop the vehicle and check the DTC.

TROUBLESHOOTING

DTC DETECTING CONDITION TROUBLE AREA

• Transmission temperature sensor terminal voltage is

less than 0.05 V for 5 minutes or more after turning

ignition switch ON.

• Transmission temperature sensor terminal voltage is

more than 4.6 V and shift range is in R, D, 2 or L for 15

minutes after starting engine.

• Transmission fluid temperature sensor or its cir-

cuit malfunction.

•TCM

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2Check Transmission Fluid Temperature Circuit

for Open.

1. Turn ignition switch OFF.

2. Disconnect TCM connectors from TCM.

3. Check for proper connect ion to tr ansmis -

sion fluid temperature sensor at terminals

C44-5 and C44-14.

If OK, check continuity between terminals C44-

5 and C44-14 of disconnected harness side

TCM connec to r.

Is continuity indicated?

Go to Step 3. BLU/RED or GRN circuit

open.

3Check Transmission Fluid Temperature Circuit

for Ground Short.

Check continuity between terminal C44-5 of

disconnected harness side TCM connector

and ground.

Is continuity indicated?

BLU/RED circuit shorted

to ground. Go to Step 4.

4Check Transmission Fluid Temperature Circuit

for IG Short.

1. Cool down A/T fluid temperature under

ambient temperature.

2. Connect TCM connectors to TCM with

ignition swi tch OF F.

3. Turn ignition switch ON.

4. Measure voltage between terminal C44-5

of TCM connector and ground.

Is it 4.6 V or more?

BLU/RED circuit shorted

to power circuit.

If circuit is OK, go to

Step 5.

Intermittent trouble or

faulty TCM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK, substitute a known-

good TCM and recheck.

2.27 DTC P0715/DTC NO.14 INPUT/TURBINE SPEED

SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory and start the engine.

3. Shift the selector lever to D range and drive vehicle at 50 km/h or more in 3rd gear for at least 5 minutes.

4. Stop the vehicle and check the DTC.

5Inspect Transmission Flu id Tem pera t ure

Sensor.

Inspect transmission temperature sensor refer-

ring to 3.14 TRANSMISSION FLUID

TEMPERATURE SENSOR, INSPECTION in

this Section.

Is result satisfactory?

Intermittent trouble or

faulty TCM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICA L

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK, substitute a known-

good TCM and recheck.

Replace transmission

fluid temperature sensor.

Step Action Yes No

C44 G99

G99-5

2.5V

WHT

BLK G99-17

1. TCM 2. Input shaft speed sensor 3. Terminal arrangement of TCM connector

(viewed from harness side)

DTC DETECTING CONDITION TROUBLE AREA

No input shaft speed sensor signal is detected although

output shaft speed sensor signals are detected. • Input shaft speed sensor or its circuit malfunc-

tion.

• Improper input shaft speed sensor installation.

• Damaged direct clutch drum.

• Foreign material attached to sensor or drum.

•TCM

TROUBLESHOOTING

Figure for Step 4

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE p erformed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

Check Input Shaft Speed Sensor Circuit.

1. Disconnect TCM connectors with ignition

switch OFF.

2. Check for proper connection to input

shaft speed sensor at G99-5 and G99-17

terminals.

3. If OK, check r esistanc e of sensor circuit.

Resistance between terminals G99-5

and G99-17 of disconnected harness

side TCM connector: 560 – 680 Ω at

20°C (68°F)

Continui ty between t erminal G99-5 /G99-

17 of disconnected harness side TCM

connector and ground: No continuity

Are check result satisf actory?

Go to Step 4. Go to Step 3.

3Inspect Input Shaft Speed Sensor.

Inspect input shaft speed sensor, refer to

3.6 INPUT SHAFT SPEED SENSOR,

INSPECTION in this Section.

Is result satisfac tory ?

WHT or BLK circuit open

or short. Replace input shaft

speed sensor.

4Check visually input shaft speed sensor and

direct clutch drum for the followings. See Fig.

No damage

No foreign material attached

Correct installation

Are they in good condition?

Intermittent trouble or

faulty TCM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK, substitute a known-

good TCM and recheck.

Clean, repair or replace.

2.28 DTC P0720/DTC NO.31 OUTPUT SPEED SENSOR (VSS) CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory and start the engine.

3. Shift the selector lever to D range and drive the vehicle at 5 0 km/h or more ve hicle speed for a t least 3

minutes.

4. Stop the vehicle check the DTC.

C44 G99

IG1 12V

YEL G99-24

YEL/BLK

BLK

1. TCM 2. Output shaft speed sensor (VSS) 3. Terminal arrangement of TCM con-

nector (viewed from harness side)

DTC DETECTING CONDITION T ROUBLE AREA

No output shaft speed sensor signal is detected although

input shaft speed sensor signals are detected while vehi-

cle is running at 5 km/h (3 mile/h) or more vehicle speed

with D, 2 or L range.

• Output shaft speed sensor or its circuit mal-

function.

• Damaged sensor gear (driven gear).

• Damaged output shaft speed sensor (VSS)

drive gea r.

•TCM

TROUBLESHOOTING

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE in this Section

performed?

Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2 Check Output Shaft Spe ed Sensor (VSS )

Power Circuit.

1. Tur n ign ition swi tc h OFF.

2. Disconnect output shaft speed sensor

connector.

3. Tur n ign ition swi tc h ON.

4. Measur e voltage between YEL/B LK wire

terminal of disconnected output shaft

speed sensor harness side connector

and ground.

Is it 10 – 14 V?

Go to Step 3. YEL/BLK wir e open or

shorted to ground.

3 Check Output Shaft Spe ed Sensor (VSS )

Ground Circuit.

1. Tur n ign ition swi tc h OFF.

2. Check continuity between BLK wire

terminal of disconnected output shaft

speed sensor harness side connector

and ground.

Is continuity indicated?

Go to Step 4. BLK wire open.

Check Output Shaft Speed Sensor (VSS)

Signal Circuit for short.

1) Disconnect TCM connectors.

2) Check continuity between YEL wire ter-

minal of disconnected output shaft

speed sens or harness side connector

and ground.

Is continuity indicated?

YEL wire shorted to

ground. Go to Step 5.

Check Output Shaft Speed Sensor (VSS)

Signal Circuit for open.

1) Check continuity between YEL wire ter-

minal of disconnected output shaft

speed sens or harness side connector

and terminal G99-24 of disconnected

harness side TCM connector.

Is continuity indicated?

Go to Step 6. YEL wire open.

Ins pect Output Shaft Speed Sensor (VSS).

Ins pect output shaft speed sensor, refe r to

3.5 OUTPUT SHA FT SPEED SENSOR,

INSPECTION in thi s Sect io n.

Is check result satisfactory?

Go to Step 7. Replace output shaft

speed sensor.

7 Check Output Shaft Spe ed Sensor (VSS )

Gears Visually.

Check output shaft speed sensor gears for the

followings.

• No damage in drive gear on differential

case

• No damage in driven gear in output shaft

speed sensor

Is result satisfactory?

Inte rmittent trouble or

Faulty TCM.

Chec k fo r inte rm i tte nt

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION

If OK, substitute a

known-good TCM and

recheck.

Replace drive gear and/

or driven gea r of output

shaft speed sensor.

Step Action Yes No

2.29 DTC P0725/DTC NO.35 ENGINE SPEED INPUT CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Start the engine and raise the engine speed to 2500 rpm.

4. Maintain engine speed of 2500 rpm for 10 seconds.

5. Release the accelerator pedal and check the DTC.

C44 G99

12V 12V

BRN

G02-16 G99-15

C42 C41 G02

1. TCM 3. Terminal arrangement of TCM

connector (viewed from harness side) 4. Terminal arrangement of ECM

connector (viewed from harness side)

2. ECM

DTC DETECTING CONDITION T ROUBLE AREA

No engine speed signal is inputted although input shaft

speed sensor signals are detected for 5 seconds. • Engine speed input signal circuit malfunction.

•TCM

•ECM

TROUBLESHOOTING

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

Check Engi ne S peed Input Si gnal Circuit for

Open.

1) Turn ig nition switch OFF.

2) Disconnect TCM and ECM connectors

from TCM and ECM.

3) Check for proper connection to TCM at

termin al G99-1 5 an d t o EC M at t er mi nal

G02-16.

4) If OK, check continuity between termi-

nals G99-15 and G02-16 of discon-

necte d harness side TCM and ECM

connectors.

Is continuity indicated?

Go to Step 3. BRN circuit open.

Check Engi ne S peed Input Si gnal Circuit for

Short.

1) Check continuity between terminal G99-

15 of disconnected harness side TCM

connector a nd ground.

Is continuity indicated?

BRN circu it sho r te d to

ground. Go to Step 4.

Check TCM Terminal Voltage.

1) Connect TCM connectors to TCM with

ignition switch OFF.

2) Turn ignition switch ON.

3) Measure voltage between terminal G99-

15 of connected harness side ECM con-

nector and ground.

Is it 8 – 14 V?

Go to Step 5. Substitute a known-

good TC M and recheck.

Check ECM Terminal Volt age.

1) Turn ig nition switch OFF.

2) Connect ECM connectors to ECM.

3) Turn ignition switch ON.

4) Measure voltage between terminal G02-

16 of connected harness side ECM con-

nector and ground.

Is it 0 – 1 V?

Interm it te nt tro u bl e or

faulty TCM or ECM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK, substitute a

known-good TCM and/

or ECM recheck.

Substitute a known-

good ECM and recheck.

2.30 DTC P0743/DTC NO.25 OR NO.26 TCC SYSTEM ELECTRICAL

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme caution.

• The road test should be carried out on a level road with 2 people, a driver and tester.

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Start the engine and warm it up to normal operating temperature.

4. Drive the vehicle in D range and repeat lock-up ON and OFF operations 4 times each, refer to the

AUTOMATIC GEAR SHIFT DIAGRAM in 1.5 TC M in th is S ECTIO N. (I n brie f, at 75 k m /h i n 4t h ge ar, th e

accelerator pedal is depressed so that the throttle opens 10% or less and is then released, repeating 4

times).

5. Decrease the vehicle speed gradually and stop the vehicle.

6. Check the DTC.

C44 G99

12V

C44-12 WHT/BLU

1. TCM 3. A/T 4. Terminal arrangement of TCM connector

(viewed from harness side)

2. TCC solenoid valve

DTC DETECTING CONDITION TROUBLE AREA

• Voltage of TCC solenoid valve TCM terminal is low

although TCM is commanding TCC solenoid to turn

ON.

• Voltage of TCC solenoid valve TCM terminal is high

although TCM is commanding TCC solenoid to turn

OFF.

• TCC solenoid valve circuit shorted to ground.

• TCC solenoid valve circuit open or shorted to

power circuit.

• TCC solenoid valve malfunction.

•TCM

TROUBLESHOOTING

Fig. for Step 3

Legend

Step Action Yes No

1 Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this section.

2 Check TCC Solenoid Valve Circuit for IG Short

or Open.

1. Turn ignition switch ON and measure

voltage between terminal C44-12 of

harness side TCM connector and ground.

Is it 0 – 1 V?

Go to Step 3. WHT/BLU circuit shorted

to power circuit or open.

3 Check TCC Solenoid Valve Resistance.

2. Turn ignition switch OFF.

3. Disconnect valve body harness connector

on transaxle.

4. Check for proper connection to solenoid

valve at WHT/BLU circuit.

5. Check resistance of solenoid valve. See

Fig. Resistance between terminal of

transaxle side valve body harness

connector and transaxle: 11 – 15 Ω (at

20°C)

Is check result satisfactory?

Go to Step 4. Replace TCC solenoid

valve or lead wire.

4 Check TCC Solenoid Valve Circuit for Ground

Short.

1. Connect valve body harness connector.

2. Disconnect TCM connectors.

3. Measure resistance between terminal C44-

12 of disconnected harness side TCM

connector and ground.

Is it 11 – 15 Ω (at 20°C)?

Intermittent trouble or

faulty T CM.

Check for inter mi tten t,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION

If OK, substitute a

known-good TCM and

recheck.

WHT/BLU circuit shorted

to ground.

5432

1. Valve body harness

connector on harness 2. Valve body harness

connector on transaxle 3. Ground (Transaxle)

2.31 DTC P0 748/DTC NO.41 OR NO.42 PRES SURE CONTROL SOLENOID

ELECTRICAL

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Start the engine and run if for 1 minute.

4. Check the DTC.

TROUBLESHOOTING

11 8

C44 G99

12V

C44-11

C44-8

BRN/YEL

LT GRN/RED

1. TCM 2. Pressure control solenoid valve 4. Terminal arrangement of TCM

connector (viewed from harness side)

3. A/T

DTC DETECTING CONDITION T ROUBLE AREA

• Too much electric flow is detected on pressure control

solenoid valve circuit.

• No electric flow is detected on pressure control sole-

noid valve circuit.

• Pressure control solenoid valve circuit shorted

to power circui t.

• Pressure control solenoid valve circuit open or

shorted to ground.

• Pressure control solenoid valve malfunction.

•TCM

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE p erformed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2Check Pressure Control Solenoid Valve Circuit

for IG Short.

1. Turn ignition switch OFF and discon nect

TCM connectors.

2. Check for proper connection to TCM at

terminals C44-11 and C44-8.

3. If OK, turn ignition switch ON and

measure voltage between terminal C44-

11 of disconnected harness side TCM

connector and ground.

Is it 0 – 1 V?

Go to Step 3. BRN/YEL or LT GRN/

RED circuit shorted to

power circuit.

Fig. for Step 3

Legend

3 Check Pressure Control Solenoid Valve

Resistance.

1. Tur n ign ition swi tc h OFF.

2. Disconnect valve body harness

connector on transaxle.

3. Check for proper connection to solenoid

valve at BRN/YEL and LT GRN/RED

circuits.

4. Check resistance of solenoid valve. See

Fig.

Resistance between terminals of

transaxle side valve body harness

connector: 5.0 – 5.6 Ω (at 20°C)

Resistance between terminal of

transaxle side valve body harness

connector and transaxle: Infinity

Is check results satisfactory?

Go to Step 4. Replace pressure control

solenoid valve or lead

wire.

4 Check Pressure Control Solenoid V alve Circuit

for Ground Short.

1. Connect valve body harness connector.

2. Check continuity between terminal C44-

11 of disconnected harness side TCM

connector and ground.

Is continuity indicated?

BRN/YEL or LT GRN/

RED circuit shorted to

ground.

Go to Step 5.

5 Check Pressure Control Solenoid V alve Circuit

for Open.

Check resistance between terminals C44-1 1

and C44-8 of disconnected harness side

TCM connector.

Is it infinity?

BRN/YEL or LT GRN/

RED circuit open. Intermittent trouble or

faulty TCM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION

If OK, substitute a known-

good TCM and recheck.

Step Action Yes No

5432

1. Valve body harness

connector on harness 2. Valve body harness

connector on transaxle 3. Ground (Transaxle)

2.32 DTC P0753/DTC NO.21 OR NO.22 SHIFT S OLENOID-A (NO.1) ELECTRICAL

Refer to 2.33 for DTC information.

2.33 DTC P0758/DTC NO.23 OR NO.24 SHIFT S OLENOID-B (NO.2) ELECTRICAL

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

WARNING:

• When performing a road test, select an area where there is no traffic and exercise extreme caution.

• Road test should be carried out on a level road with 2 persons, a driver and tester.

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Start the engine and shift the selector lever to D range.

4. Increase the vehicle speed until 3rd or 4th gear is automatically selected.

5. Decrease vehicle speed and stop the vehicle.

6. Repeat Step 4 and Step 5 at least 4 times.

7. Check the DTC.

C44 G99

12V

C44-3 BLK/YEL

12V

C44-4 BRN 4

1. TCM 3. Shift solenoid valve-B (No.2) 5. Terminal arrangement of TCM

connector (viewed from

harness side)

2. Shift solenoid valve-A

(No.1) 4. A/T

DTC DETECTING CONDITION T ROUBLE AREA

• Voltage of shift solenoid valve TCM terminal is low

although TCM is commanding shift solenoid valve to

turn ON.

• Voltage of shift solenoid valve TCM terminal is high

although TCM is commanding shift solenoid valve to

turn OFF.

• Shift solenoid valve circuit shorted to ground.

• Shift solenoid valve circuit open or shorted to

power circuit.

• Shift solenoid valve malfunction.

•TCM

TROUBLESHOOTING

Fig. for Step 3

Legend

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE performed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in thi s Sec tio n.

2Check Shift Solenoid Valve Circuit for IG Short.

1. Turn ignition switch OFF and disconnect

TCM connectors.

2. Check for proper connection to TCM at

terminal C44-4 or C44-3 of TCM connector .

3. If OK, tur n ig niti on swi tch ON and meas ur e

voltage between terminal C44-4 or C44-3

of disconnected harness side TCM

connector and ground.

Is it 0 – 1 V?

Go to Step 3. BRN or BLK/YEL circuit

shorted to power circuit.

3Check Shift Solenoid Valve Resistance.

1. Turn ignition switch OFF.

2. Disconnect valve body harness connector

on transaxle.

3. Check for proper connection to solenoid

valve at BRN or BLK/YEL circuit.

4. Check resistance of solenoid valves. See

Fig.

Resistance between terminal of transaxle

side valve body harness connector and

transaxle: 11 – 15 Ω (at 20°C)

Is check result satisfactory?

Go to Step 4. Replace shift solenoid

valve or lead wire.

Check Shift Solenoid Valve Circuit for Ground

Sho rt or Op en .

1. Connect valve body harness connector.

2. Measure resistance between terminal C44-

4 or C44-3 of disconnected harness side

TCM connector and ground.

Is it 11 – 15 Ω (at 20°C)?

Intermittent trouble or

faulty T CM.

Check for inter mi tten t,

refer to SSection 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION

If OK, substitute a

known-good TCM and

recheck.

BRN or BLK/YEL circuit

shorted to ground or

open.

5432

1. Valve body harne ss

connector on harness 3. Shift solenoid valve-A (No.1) ter-

minal 5. Ground (Transaxle)

2. Valve body harne ss

connector on transaxle 4. Shift solenoid valve-B (No.2) ter-

minal

2.34 DTC P0785/DTC NO.13 TIMING SOLENOID

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Start the engine and shift the selector lever to N range.

4. Shift the selector lever from N range to D range and repeat 3 times.

5. Check the DTC.

C44 G99

12V

C44-10 WHT/RED

1. TCM 3. A/T 4. Terminal arrangement of TCM

connector (viewed from harness side)

2. Timing solenoid valve

DTC DETECTING CONDITION T ROUBLE AREA

• Voltage of timing solenoid valve TCM terminal is low

although TCM is commanding timing solenoid valve to

turn ON.

• Voltage of timing solenoid valve TCM terminal is high

although TCM is commanding timing solenoid valve to

turn OFF.

• Timing solenoid valve circuit shorted to ground.

• T iming solenoid valve circuit open or shorted to

power circuit.

• Timing solenoid valve malfunction.

•TCM

TROUBLESHOOTING

Legend

Step Action Yes No

1 Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE p erformed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2 Check Timing Solenoid Valve Circuit for IG

Short or Open.

1. Turn ignition switch ON and measure

voltage between terminal C44-10 of

harness side TCM connector and

ground.

2. Is it 0 – 1 V?

Go to Step 3. WHT/RED circuit shorted

to power circuit or open.

Check Timing Solenoid Valve Resistance

1. Tur n ign ition swi tc h OFF.

2. Disconnect valve body harness

connector on transaxle.

3. Check for proper connection to solenoid

valve at WHT/RED circuit.

4. Check resistance of solenoid valve. See

Fig.

Resistance between terminal of

transaxle side valve body harness

connector and transaxle:

11 – 15 Ω (at 20°C)

Is check result satisfactory?

Go to Step 4. Replace timing solenoid

valve or lead wire.

4 Check Timing Solenoid Valve Circuit for

Ground Short.

1. Connect valve body harness connector.

2. Disconnect TCM connectors.

3. Measure resistance between terminal

“C44-10” of disconnected harness side

TCM connector and ground.

Is it 11 – 15 Ω (at 20°C)

Intermittent trouble or

faulty T CM.

Check for inter mi tten t,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK , substitute a kn ow n -

good TCM and recheck.

WHT/RED circuit shorted

to ground.

5432

1. Valve body harness

connector on harness 2. Valve body harness

connector on transaxle 3. Ground (Transaxle )

2.35 DTC P1700/DTC NO.32 OR NO.33 THROTTLE POSITION SIGNAL

CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Turn the ignition switch ON.

4. Depress the accelerator pedal fully and keep it depressed for 10 seconds.

5. Release the accelerator pedal and wait for 10 seconds.

6. Check the DTC.

C44 G99

12V

LT GRN/RED

G02-15 G99-6

C42 C41 G02

1. TCM 3. Terminal arrangement of TCM con-

nector (viewed from harness side) 4. Terminal arrangement of ECM con-

nector (viewed from harness side)

2. ECM

DTC DETECTING CONDITION T ROUBLE AREA

• Too short low signal of pulse signal from ECM to TCM

continues out of specification.

• Too long low signal of pulse signal from ECM to TCM

continues out of specification.

• Throttle position sensor or its circuit malfunc-

tion.

• Throttle position signal circuit from ECM to

TCM open or short.

•TCM

•ECM

TROUBLESHOOTING

Step Action Yes No

1 Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE p erformed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2 Is there DTC related to throttle position sensor

(P0120)? Go to corresponding DTC

Flow Tab le in Secti on 6. Go to Step 3.

3 Check Throttle Position Signal Circuit for IG

Short.

1. Tur n ign ition swi tc h OFF.

2. Disconnect TCM and ECM connectors

from TCM and ECM.

3. Check proper connection to TCM at

terminal G99-6 and to ECM at terminal

G02-15.

4. If OK, turn ignition switch ON and

measure voltage between terminal G99-

6 of disconnected harness side TCM

connector and ground.

Is it 10 – 14 V?

LT GRN/RED circuit

shorted to power circuit. Go to Step 4.

4 Check Throttle Position Signal Circuit for

Open.

1. Tur n ign ition swi tc h OFF.

2. Check continuity between terminal G99-6

of disconnected harness side TCM

connec tor and terminal G 02-15 of discon -

nected harness side ECM connector.

Is continuity indicated?

Go to Step 5. LT GRN/RED circuit

open.

5 Check Throttle Position Signal Circuit for

Ground Short.

Check continuity between terminal G99-6 of

disconnected harness side TCM connector

and ground.

Is continuity indicated?

LT GRN/RED circuit

shorted to ground. Intermittent trouble or

faulty TCM or ECM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK, substitute a known-

good TCM or ECM and

recheck.

2.36 DTC P1702/DTC NO.52 INTERNAL MALFUNCTION OF TCM

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Wait 10 seconds after turning the ignition switch ON, then check the DTC.

TROUBLESHOOTING

DTC DETECTING CONDITION T ROUBLE AREA

Calculation of current data stored in TCM is not correct

comparing with pre-stored checking data in TCM. TCM

Step Action Yes No

1Is DTC P1702/DTC No.52 detected after per-

forming DTC CONFIRMATION

PROCEDURE?

Faulty TCM.

Replace TCM. Could be a temporary

malfunction of the TCM.

2.37 DTC P1705/ DTC NO.51 ENGINE COOLANT TEMPERATURE SIGNAL

CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in TCM memory.

3. Wait 2 minutes after turning the ignition switch ON, then check the DTC.

C44 G99

12V

GRY/RED

G02-17 G99-7

C42 C41 G02

1. TCM 3. Terminal arrangement of TCM

connector (viewed from harness

side)

4. Terminal arrangement of ECM

connector (viewed from harness

side)

2. ECM

DTC DETECTING CONDITION TROUBLE AREA

• Too long high signal of pulse signal from ECM to TCM

continue s out of speci fic ati on.

• Too long low signal of pulse signal from ECM to TCM

continue s out of speci fic ati on.

• Too long or short low signal of pulse signal from ECM

to TCM is detected in continues 8 pulses.

• Engine coolant temperature sensor or its circuit

malfunction.

• Engine coolant temperature signal circuit from

ECM to TCM open or short.

•TCM

•ECM

TROUBLESHOOTING

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE DIAG-

NOSTIC FLOW TABLE performed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2Is there DTC related to throttle position sensor

(P0115)? Go to corresponding DTC

Flow Table in Section 6. Go to Step 3.

3Check Engine Coolant Temperature Signal

Circuit for IG Short.

1. Turn ignition switch OFF.

2. Disconnect TCM and ECM connectors

from TCM and ECM.

3. Check proper connection to TCM at

terminal G99-7 and to ECM at terminal

G02-17.

4. If OK, turn ignition switch ON and

measure voltage between terminal G99-

7 of disconnected harness side TCM

connector and ground.

Is it 10 – 14 V?

GRY/RED circuit shorted

to power circuit. Go to Step 4.

4Check Engine Coolant Temperature Signal

Circuit for Open.

1. Turn ignition switch OFF.

2. Check continuity between terminal G99-

7 of disconnected harness side TCM

connector and terminal G02-17 of dis-

connected harness side ECM connector.

Is continui ty indic ate d?

Go to Step 5. GRY/RED circuit open.

5Check Engine Coolant Temperature Signal

Circuit for Ground Short.

Check continuity between terminal G99-7 of

disconnected harness side TCM connector

and ground.

Is continui ty indic ate d?

GRY/RED circuit shorted

to ground. Go to Step 6.

6Inspect Engine Coolant Temperature Sensor.

Inspect engine coolant temperature sensor

referring to 3.8 ENGINE COOLANT

TEMPERATURE SENSOR, INSPECTION.

Is inspection result OK ?

Intermit tent tr ouble or

faulty TCM or ECM.

Check for intermittent,

refer to SSection 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION

If OK, substitute a known-

good TCM or ECM and

recheck.

Replace eng ine cool ant

temperature sensor.

2.38 DTC P173 0/DTC NO.64 ENGINE TORQUE SIGNA L CIR CUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Wait 1 minute after turning the ignition switch ON, then check the DTC.

C44 G99

12V

GRY/YEL

G02-5 G99-23

C42 C41 G02

1. TCM 3. Terminal arrangement of TCM

connector (viewed from harness side) 4. Terminal arrangement of ECM

connector (viewed from harness side)

2. ECM

DTC DETECTING CONDITION T ROUBLE AREA

• Too short low signal of pulse signal from ECM to TCM

continues out of specification.

• Too long low signal of pulse signal from ECM to TCM

continues out of specification.

• Engine torque signal circuit malfunction.

•TCM

•ECM

TROUBLESHOOTING

Step Action Yes No

1 Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE performed? Go to Step 2.

Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

Check Engine Torque Signal Circuit for IG

Short.

1. Turn ignition switch OFF.

2. Disconnect TCM and ECM connectors

from TCM and ECM.

3. Check proper connections to TCM at

terminal G99-23 and to ECM at terminal

G02-5.

4. If OK, turn ignition switch ON and

measure voltage between terminal G99-

23 of disconnected harness side TCM

connector and ground.

Is it 10 – 14 V?

GRY/YEL circuit shorted

to power circuit. Go to Step 3.

3 Check Engine Torque Signal Circuit for Open.

1. Turn ignition switch OFF.

2. Check continuity between terminal G99-

23 of disconnected harness side TCM

connec tor and ter minal G 02-5 of dis con-

nected harness side ECM connector.

Is continui ty indic ate d?

Go to Step 4. GRY/YEL circuit open.

4 Check Engine Torque Signal Circuit for

Ground Sho rt .

Check continuity between terminal G99-23 of

disconnected harness side TCM connector

and ground.

Is continuity indicated?

GRY/YEL circuit shorted

to ground. Intermittent trouble or

faulty TCM or ECM.

Check for intermittent,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION

If OK, substitute a

known-good TCM or

ECM and recheck.

2.39 DTC P1895/DTC NO.27 TORQUE REDUCTION SIGNAL CIRCUIT MALFUNCTION

WIRING DIAGRAM

Legend

DTC DETECTING CONDITION AND TROUBLE AREA

DTC CONFIRMATION PROCEDURE

1. Connect Tech 2 to the DLC with the ignition switch OFF.

2. Clear the DTC in the TCM memory.

3. Wait 1 minute after turning the ignition switch ON, then check the DTC.

C44 G99

12V

PNK G99-18G02-12

C42 C41 G02

1. TCM 3. Terminal arrangement of TCM

connector (viewed from harness side) 4. Terminal arrangement of ECM

connector (viewed from harness side)

2. ECM

DTC DETECTING CONDITION T ROUBLE AREA

V oltage of torque reduction signal circuit TCM terminal is

low although TCM does not require ECM to reduce

engine torque.

• Torque reduction signal circuit malfunction.

•TCM

•ECM

TROUBLESHOOTING

Step Action Yes No

1Was 2.4 AUTOMATIC TRANSAXLE

DIAGNOSTIC FLOW TABLE p erformed? Go to Step 2. Go to 2.4 AUTOMATIC

TRANSAXLE

DIAGNOSTIC FLOW

TABLE in this Section.

2Check Torque Reduction Signal Circuit for

Open.

1. Tur n ign ition swi tc h OFF.

2. Disconnect TCM and ECM connectors

from TCM and ECM.

3. Check continuity between terminal G99-

18 of disconnected harness side TCM

connec tor and terminal G 02-12 of discon -

nected harness side ECM connector.

Is continuity indicated?

Go to Step 3. PNK circuit open.

3Check Torque Reduction Signal Circuit for

Ground Short.

Check continuity between terminal G99-18 of

disconnected harness side TCM connector

and ground.

Is continuity indicated?

PNK circuit shorted to

ground. Go to Step 4.

4Check Power Supply from ECM.

1. Connect ECM connectors to ECM.

2. Tur n ign ition swi tc h ON.

3. Measure voltage between terminal G02-

12 of connected harness side ECM

connector and ground.

Is it 9 – 14 V?

Intermittent trouble or

faulty TCM or ECM.

Check for inter mi tten t,

refer to Section 0A,

1.7 ELECTRICAL

CIRCUIT INSPECTION

PROCEDURE.

INTERMITTENT AND

POOR CONNECTION.

If OK , substitute a kn ow n -

good TCM or ECM and

recheck.

Faulty ECM.

2.40 TEC H 2 DATA

As the data values given below are standard values estimated on the values obtained from the normal opera-

tion of veh icles us ing Tec h 2, use them as referen ce values onl y. Even when the vehi cle is in goo d condi tion,

there may be cases where the checked value does not fall within each specified data range. Therefore, an

assessment of problems should not be made using this data alone.

Also, the conditi ons i n the table below th at can b e chec ked usin g Tech 2 are those det ected b y the TC M and

output from the TCM as commands. There may be cases where the automatic transaxle or actuator is not

operating (in the condition) as indicated by Tech 2.

NOTE: The foll owing Tech 2 data rel ati ng to th e au tom ati c t ran sax le ca n be ch ec ke d on ly by c omm uni c atin g

with the TCM.

Tech 2 DATA VEHICLE CONDITION NORMAL CONDITION

/REFERENCE VALUES

GEAR POSITION Ignition switch ON Selector lever is in P position P or N

Selector lever is in R position R

Selector lever is in N position P or N

Selector lever is in D position 1st

Selector lever is in 2 position 1st

Selector lever is in L position 1st

THROTTLE

POSITION Ignition switch ON Accelerator pedal is released 0%

Accelerator pedal is

depressed 0 – 100%

(V aries depending on depressed

value)

INPUT SHAFT

SPEED Ignition switch ON and engine stop 0 RPM

At 60 km/h constant speed, O/D off switch ON, 20%

or less throttle opening and 3rd gear (D range) Approx. 2350 RPM

OUTPUT SHAFT

SPEED At vehicle stop 0 RPM

At 60 km/h constant speed, O/D off switch ON, 20%

or less throttle opening and 3rd gear Approx. 2350 RPM

VEHICLE SPEED At vehicle stop 0 km/h

BATTERY

VOLTAGE Ignition switch ON and engine stopped Battery voltage is displayed

(8 – 16 V)

TRANSMISSION

FLUID

TEMPERATURE

After driving at 60 km/h for 15 minutes or more, and

A/T fluid temperature around sensor reaches 70 –

80°C

70 – 80°C

PCS DUTY CYCLE At vehicle stop, closed throttle, engine idle speed

and 1st gear 0%

ENGINE SPEED At engine idle speed Engine idle speed is displayed

ENGINE

COOLANT

TEMPERATURE

Ignition switch ON Engine coolant temperature is

displayed

ENGINE TORQUE Ignition switch ON and engine stop 0 Nm

OVERDRIVE OFF

SWITCH Ignition switch ON O/D off switch OFF OFF

O/D off switch ON ON

SELECTOR

POSITION Ignition switch ON Selector lever is in P position P

Selector lever is in R position R

Selector lever is in N position N

Selector lever is in D position D

Selector lever is in 2 position 2

Selector lever is in L position L

SHIFT

SOLENOID-A At vehicle stop ON

At 60 km/h constant speed, O/D off switch ON, 20%

or less throttle opening and 3rd gear OFF

TECH 2 DATA DEFINITIONS:

Gear Position

Current gear position computed by throttle position coming from the ECM and vehicle speed.

Throttle Position (%)

Throttle opening ratio computed by duty pulse signal from the ECM.

Input Shaft Speed (rpm)

Input shaft revolution computed by reference pulses coming from the input shaft speed sensor on the tran-

saxle case.

Outp ut Shaft Speed (rpm)

Output shaft revolution computed by reference pulses coming from the output shaft speed sensor (VSS) on

the transaxle case.

Vehicle Speed (km/h)

Vehi cle speed c omputed by reference p ulse signa ls comi ng from the Vehicle Speed Sensor on t he transa xle

case.

Battery Voltage (V)

Battery voltage read by the TCM as analogue input signal by the TCM.

SHIFT

SOLENOID-A

FEEDBACK

At vehicle stop ON

At 60 km/h constant speed, O/D off switch ON, 20%

or less throttle opening and 3rd gear OFF

SHIFT

SOLENOID-B At vehicle stop ON

At 60 km/h constant speed, O/D off switch ON, 20%

or less throttle opening and 3rd gear OFF

SHIFT

SOLENOID-B

FEEDBACK

At vehicle stop ON

At 60 km/h constant speed, O/D off switch ON, 20%

or less throttle opening and 3rd gear OFF

TCC SOLENOID

VAVLE At 5 km/h constant speed, O/D off switch ON, closed

throttle and 1st gear OFF

At 100km/h constant speed, O/D off switch OFF,

20% or less throttle opening and 4th gear ON

TCC SOLENOID

FEEDBACK At 5 km/h constant speed, O/D off switch ON, closed

throttle and 1st gear OFF

At 100 km/h constant speed, O/D off switch OFF,

20% or less throttle opening and 4th gear ON

TIMING

SOLENOID Ignition switch ON and selector lever is in N range OFF

For about 0.5 sec. while on gear shifting between 3rd

and 4th ON

TIMING

SOLENOID

FEEDBACK

Ignition switch ON and selector lever is in N range OFF

For about 0.5 sec. while on gear shifting between 3rd

and 4th ON

DRIVING MODE Ignition switch ON Selector lever is in P position P/N

Selector lever is in R position DRIVE

Selector lever is in N position P/N

Selector lever is in D position DRIVE

Selector lever is in 2 position DRIVE

Selector lever is in L position DRIVE

A/C SWITCH Ignition switch ON and air conditioner switch OFF OFF

BRAKE SWITCH Ignition switch ON Brake pedal is depressed ACTIVE

Brake pedal is released INACTIVE

TORQUE

REDUCTION While on gear upshifting with 10% or more throttle

opening ACTIVE

Under condition of not shifting gear INACTIVE

Tech 2 DATA VEHICLE CONDITION NORMAL CONDITION

/REFERENCE VALUES

Transmission Fluid Temperature (°C)

Automat ic Trans mission Fluid temperature dec ided by signa l from the tr ansmission fl uid temperatur e sensor

installed on valve body.

PCS Duty Cycle (%)

Electric current value ratio between the electric current value being outputted from the TCM to the solenoid

and the maximum value that can be outputted by TCM.

Engine Speed (rpm)

Engine speed computed by reference pulses from the Crankshaft Position Sensor.

Engine Coolant Temperature (°C)

Engine coolant temperature computed by duty pulse signal from the ECM.

Engine Torque (Nm)

Engine torque computed by duty pulse signal outputted from the ECM.

Overdrive Off Switch

Inputted signal from O/D off switch on selector knob.

ON: O/D off switch ON.

OFF: O/D off switch OFF.

Selector Position

Transaxle range detected by a signal feed from the transmission range sensor.

Shift Solenoid-A

ON: ON command being outputted to the Shift Solenoid Valve-A (No.1).

OFF: ON command not being outputted to the Shift Solenoid Valve-A (No.1).

Shift Solenoid-A Feedback

ON: Current flowing to the Shift Solenoid Valve-A (No.1).

OFF: Current not flowing to the Shift Solenoid Valve-A (No.1).

Shift Solenoid-B

ON: On command being outputted to the Shift Solenoid Valve-B (No.2).

OFF: ON command not being outputted to the Shift Solenoid Valve-B (No.2).

Shift Solenoid-B Feedback

ON: Current flowing to the Shift Solenoid Valve-B (No.2).

OFF: Current not flowing to the Shift Solenoid Valve-B (No.2).

TCC Solenoid Valve

ON: ON command being outputted to the TCC shift solenoid valve.

OFF: ON command not being outputted to the TCC shift solenoid valve.

TCC Solenoid Feedback

ON: Current flowing to the TCC solenoid valve.

OFF: Current not flowing to the TCC solenoid valve.

Timing Solenoid

ON: ON command being outputted to the Timing Solenoid Valve.

OFF: ON command not being outputted to the Timing Solenoid Valve.

Timing Solenoid Feedback

ON: Current flowing to the Timing Solenoid Valve.

OFF: Current not flowing to the Timing Solenoid Valve.

Driving Mode

ON: Signal which the TCM requires the ECM to increase idle speed.

OFF: Signal which the TCM does not require the ECM to increase idle speed.

A/C Switch

ON: Signal which informs that the air conditioner compressor is turned ON.

OFF: Signal which informs that the air conditioner compressor is not turned ON.

Brake Switch

Inputted signal from the brake light switch on the brake pedal bracket.

ON: Brake pedal depressed.

OFF: Brake pedal released.

Torque Reduction

ON: Signal which the TCM requires the ECM to reduce output torque at shifting gear

OFF: Signal which the TCM does not require the ECM to reduce output torque.

2.41 INSPECTION OF TCM AND ITS CIRCUITS

The TCM and its circuits can be checked at the TCM wiring

connectors by measuring voltage and resistance.

CAUTION: The TCM cannot be checked by itself, it is

strictly prohibited to connect voltmeter or ohmmeter to

the TCM with the connector disconnected from it.

INSPECTION

1. Remove the TCM (1) from the vehicle, refer to

1.5 TRANSMISSION CONTROL MODULE (TCM) in

this Section.

2. Connect the TCM connectors (2) to the TCM.

3. Check the voltage at each terminal with the connectors

connected and the voltmeter grounded (3).

NOTE: As each ter minal v oltage i s affected by ba tter y vo lt-

age, confirm that it is 11 V or more when the ignition switch

is ON.

TERMINAL ARRANGEMENT OF TCM CONNECTOR (VIEWED FROM HARNESS SIDE)

TERMINAL CIRCUIT STANDARD

VOLTAGE CONDITION

G99 1 Tr an smissi on ra nge sens or

(R range) 8 – 14 V Ignition switch ON, selector lever in “R” range

0 – 1 V Ignition switch ON, selector lever in other than

R range

2 Transmis sion ra nge sens or

(P range) 8 – 14 V Ignition switch ON, selector lever in P range

0 – 1 V Igni tion swit ch ON, sel ector le ver in oth er than P

range

3 O/D off switch 0 – 1 V O/D off switch is held in.

8 – 14 V O/D off switch is released.

4Blank – –

5 Input shaft speed sensor (+) 2 – 3 V Ignition switch ON, engine at stop

6 Throttle opening signal (from

ECM) 0 – 1 V Ignition switch ON (Signal from ECM is 128 Hz

active low duty pulse. Duty ratio varies as throt-

tle valve is opened gradually.

Duty On time: 0.78 ms (throttle opening 0%)

6.24 ms (throttle opening 100%)

8 – 14 V

G99 7 Engine coolant temperature

signal (from ECM) 0 – 1 V Ignition switch ON (Signal from ECM is active

low duty pulse. Duty ratio varies depending on

engine coolant temperature.

Duty On time: 850 ms (20°C )

1450 ms (80°C )

8 – 14 V

8 Transmis sion ra nge sens or

(D range) 8 – 14 V Ignition switch ON, selector lever in D range

0 – 1 V Ignition switch ON, selector lever in other than

D range

9 Transmis sion ra nge sens or

(N range) 8 – 14 V Ignition switch ON, selector lever in N range

0 – 1 V Ignition switch ON, selector lever in other than

N range

10 O/D OFF light 0 – 1 V Igniti on switch ON (lamp turned ON)

9 – 14 V Ignition switch ON (lamp turned OFF)

11 Blank – –

12 D range signal 9 – 14 V Ignition switch ON, selector lever in P or N

range

0 – 1 V Igni ti on sw i t ch ON , s el e ct or le ver in R, D, 2 or L

range

13 Blank – –

14 Air conditioner compressor

signal 0 – 1 V Ignition switch ON, A/C compressor turned ON

8 – 14 V Ignition switch ON, A/C compressor turned OFF

15 Engine speed signal 0 – 1 V Ignition switch ON, engine at stop

0 – 1 V While engine running (Signal from ECM is

pulse. Pulse frequency varies depending on

engine speed. (3000 rpm = 100 Hz))

8 – 14 V

16 Blank – –

17 Input shaft speed sensor (–) 2 – 3 V Ignition switch ON

18 Torque reduction signal 9 – 14 V Ignition switch ON

19 Blank – –

20 Transm is sion ra nge sens or

(L range) 8 – 14 V Ignition switch ON, selector lever in L range

0 – 1 V Ignitio n swit ch ON, s elect or leve r in ot her t han L

range

21 Transm is sion ra nge sens or

(2 range) 8 – 14 V Ignition switch ON, selector lever in 2 range

0 – 1 V Ignitio n swit ch ON, s elect or leve r in ot her t han 2

range

22 Blank – –

23 Engine torque signal 0 – 1 V Ignition switch ON (Signal from ECM is 128 Hz

duty pulse. Duty ratio varies depending on

engine torque.)8 – 14 V

24 Output shaft speed sensor 0 – 1 V Ignition switch ON and vehicle running (Signal

from sensor is pulse. Pulse frequency varies

depending on vehicle speed. (4 pulses are gen-

erated per 1 sensor shaft revolution.))8 – 14 V

25 Blank – –

26 Blank – –

G99 27 Data link connector 0 – 1 V Ignition switch ON

8 – 14 V

28 Vehicle speed output 0 – 1 V Ignition switch ON and vehicle running (Output

signal is pulse. Pulse frequency varies depend-

ing on vehicle speed.)8 – 14 V

TERMINAL CIRCUIT STANDARD

VOLTAGE CONDITION

C44 1 Blank – –

2Blank – –

3 Shift solenoid valve-B (No.2) 9 – 14 V Ignition switch ON, selector lever in P range

4 Shift solenoid valve-A (No.1) 9 – 14 V Ignition switch ON, selector lever in P range

5 Transmission temp er atu re

sensor (+) 4.5 – 4.9 V Ignition switch ON, fluid temperature is –30°C

3.3 – 3.7 V Ignition switch ON, fluid temperature is 10°C

0.3 – 0.5 V Ignition switch ON, fluid temperature is 110°C

0.1 – 0.3 V Ignition switch ON, fluid temperature is 145°C

6 Diagnosis switch 8 – 14 V Ignition switch ON

7Blank – –

8 Pressure control solenoid

valve (ground) 0 – 2.5 V Ignition switch ON (Signal is duty pulse. Duty

ratio varies as throttle valve opening.)

9Blank – –

10 Timing solenoid valve 0 – 1 V Ignition switch ON

11 Pressure control solenoid

valve (+) 0 – 1 V Ignition switch ON (Output signal is duty pulse.

Duty ratio varies as throttle valve opening.)

9 – 14 V

12 TCC s olenoid valve 0 – 1 V Ignition switch ON

13 Power source for back-up 10 – 14 V Constantly

14 Transm issi on temp er atu re

sensor (ground) 0 – 1 V Ignition switch ON

15 Ground 0 – 1 V Ignition switch ON

16 Brake light switch 8 – 14 V Ignition switch ON, brake pedal depressed

0 – 1 V Ignition switch ON, brake pedal released

17 Blank – –

18 Blank – –

19 Ground 0 – 1 V Ignition switch ON

20 Power source 10 – 14 V Ignition switch ON

TERMINAL CIRCUIT STANDARD

VOLTAGE CONDITION

3. ON-VEHICLE SERVICE

3.1 MA INTENANCE SE RVICE

FLUID LEVEL CHECK AT NORMAL OPERATING (HOT) TEMPERATURE (HOT CHECK)

Inspection

1. Stop the vehicle and place it on level ground.

2. Apply the parking brake and place chocks against the

wheels.

3. With the selector at P position, start the engine.

4. Warm up the en gine until the A/T flui d reaches norma l

operating temperature (70 – 80°C). As a guide, this

should occur when the engine reaches normal

operating temperature.

5. Keep the engine idling and shift the selector slowly to L

and back to P position.

6. With the engine idling, pull out the fluid level gauge,

wipe it with a clean cloth and put it back into place.

For the operation of the select lever, refer to the figure.

A - Shift the selector with its button pushed in.

B - Shift the selector without pushing the button in.

7. Pull out the fluid level gauge (1) again and check the

fluid. The lowest fluid level should be between FULL

HOT (2) and LOW HOT (3). If it is below LOW HOT,

add an equivalent of DEXRON

-III up to FULL HOT.

Automatic transaxle fluid

: An equivalent of DEXRON

-III or DEXRON

-IIE

NOTE:

• Do not race the engine while checking the fluid level.

• Do no t overfill. Overfilling can cause foaming and loss

of fluid through the breather. Slippage and transaxle

failure can result .

• Bringing the level from LOW HOT to FULL HOT

require s 0.4 lit re s.

• If the vehicle was driven under heavy load i.e. pulling a

trailer, the fluid level should be checked about half an

hour after it has stopped.

FLUID LEVEL CHECK AT ROOM (COLD) TEMPERATURE (COLD CHECK)

Inspection

The fluid level can be checked temporarily at room (cold)

temperature (20 – 30°C). This level check should be con-

sidered as preparation before performing a level check

under normal the operating (hot) temperature. The check-

ing procedure is the same as NORMAL OPERATING

TEMPERATURE FLUID CHECK as described previously. If

the fluid level i s between FULL COLD ( 1) and LOW COLD

(2), proceed to test drive. When the fluid temperature has

reached normal operating (hot) temperature, check the

fluid level again and adjust it as necessary.

CAUTION:

Fluid lev el check at room (cold ) temperature is recom-

mended only as preparation for a level check under

normal (hot) operating conditions.

Failure to perform a fluid level check under normal

(hot) operating temperatures may result in damage to

the A/T transaxle.

FLUID CHANGE

1. Raise the vehicle on a hoist.

2. When engine is cool, remove the drain plug (1) from

transaxle housing (2) and drain the A/T fluid.

3. Install the drain plug (1).

4. Lower the ve hicle and reple nish th e correct am oun t of

an equivalent of DEXRON

-III.

5. Check the fluid level (!), refer to

FLUID LEVEL CHECK.

Automatic transaxle fluid

: An equivalent of DEXRON

-III

A/T FLUID DRAIN PLUG (a)

TIGHTENING TORQUE 17 Nm

AUTOMATIC TRANSAXLE FLUID

CAPACITY

WHEN DRAINING FROM DRAIN PLUG

WHEN OVERHAULING 3.3 LITRES

5.6 LITRES

A/T FLUID COOLER HOSES

The rubber hoses (1,2) for the A/T fluid cooler should be

replaced at specified intervals. When replacing them, be

sure to note the following.

• to replace clamps at the same time

• to insert hose as far as its limit mark

• to clamp hose s securely

3.2 SELECTOR LEVE R

Legend

INSPECTION

Check the selector lever for smooth and clear-cut move-

ment and position indicator for correct alignment.

For the operation of the select lever, refer to the figure.

A - Shift the selector with its button pushed in.

B - Shift the selector without pushing the button in.

1. Selector lever assembly 3. Screw 5. Illumination lamp assembly

2. Knob assembly 4. Indicator assembly 6. Connector

3.3 SELECT CABLE

Legend

REMOVAL

1. Remove the parking brake lever cover.

2. Remove the console box.

3. Disconnect the select cable from the selector lever and

then detach from the bracket.

4. Remove the clip and disconnect the select cable from

the manual select lever.

5. Remove the select cable retainer from the dash panel.

INSTALLATION

Install the select cable by reversing the removal procedure.

The import ant steps in the installation are as follows.

• Apply grease to the pin and cable joint.

• Tighten bolts to specified torque.

• Adjusting procedure is as follows:

1. Selector lever assembly 6. Clip 9. Selector lever pin

2. Select cable 7. Select cable retainer bolt : Apply lithium grease

3. Select cable retainer 8. Manual select lever pin

: Apply lithium grease all

around pin (0.15 g)

all around pin (0.15 g)

4. Cable bracket Tightening torque

5. Manual select lever

ADJUSTMENT

1. Shift the manual shift lever to N range (transmission

range sensor N range).

2. Remove the adjuster (cable end) from the selector

lever pin of the selector lever assembly.

3. Release the lock plate (1) which restricts the

movement of the cable end holder (2).

4) Push the cable end holder (1) out from the eye-end

(2) using an appropriate tool (3) to disengage

cable.

5. Shift the selector lever to N position.

6. Apply grease to the selector lever pin and install

adjuster (cable end) to it.

Lithium grease

7. With both the selector lever and the transmission range

sensor kept at N position, drive the cable end holder

(1) in until it locks the cable.

8. Slide the lock plate (2) to secure the cable end holder

in position .

9. After the select cable is installed, che ck for the follow-

ing.

10. Push vehicle with selector lever shifted to P range.

• Vehicle should not move.

• Vehicle cannot be driven in N range.

• Vehicle can be driven in D, 2 and L ranges.

• Vehicle can be backed in R range.

“P” “R” “N” “D” “2” “L”

3.4 TRANSMISSION RANGE SENSOR (SHIFT SWITCH)

ADJUSTMENT AND INSPECTION

1. Shift the manual select lever (4) to N range.

2. Check that the needle direction shaped on the lock

washer (2) and N reference line (1) on the transmission

range sensor are aligned. If not, loosen sensor bolts

(3) and align them.

3. Check that the engine starts in N and P ranges but it

does not start in D, 2, L or R range. Also, check that

the back-up lamp lights in R range.

If the fault cannot be corrected by adjustment, disconnect

the transmission range sensor connector and check that

continuity exists as shown by moving manual select lever.

3.5 OUTPUT SHAFT SPEED SENSOR (VSS)

REMOVAL

1. Disconnect the negative cable at the battery.

2. Disconnect the output shaft speed sensor connector

(2).

3. Remove the output shaft speed sensor (VSS) (1) by

removing its bolt.

TRANSMISSION RANGE SENSOR

BOLTS (a)

TORQUE SPECIFICATION 5.5 Nm

INSPECTION

1. Connect the positive cable of a 12 volt battery to the

“A” terminal of the sensor and the ground cable to the

“C” terminal. Using a voltmeter, check the voltage

between “B” terminal and “C” terminal with the output

shaft speed sensor (VSS) driven gear rotated.

If the measured voltage (pulse signal) is not as speci-

fi ed, replace sensor.

2. Check output shaft speed sensor (VSS) driven gear (1)

for wear.

Replace if necessary.

INSTALLATION

1. Apply A/T fluid to the output shaft speed sensor O-ring.

2. Install the output shaft speed sensor (VSS) (1) to the A/

T case and tighten bolt to specified torque.)

3. Connect the output shaft speed sensor connector (2) to

the output shaft speed sensor (1).

4. Connect the negative cable to the battery.

OUTPUT SHAFT SPEED SENSOR

(VSS) OUTPUT VOLTAGE PULSE SIGNAL

ALTERNATIING

BETWEEN 0 - 1 V

& 10 - 14 V

OUTPUT SHAFT SENSOR (VSS) BOLT (a)

TORQUE SPECIFICATION 13 Nm

3.6 INPUT SHAFT SPEE D SENSOR

INSPECTION

1. Disconnect negative cable at battery.

2. Disconne ct the input shaft spe ed sensor conne ctor (2)

from the speed sensor (1).

3. Check the resistance between the input shaft speed

sensor terminals.

REMOVAL

1. Disconnect the negative cable at the battery.

2. Disconnect the input shaft speed sensor connector (2).

3. Remove the input shaft speed sensor (1) by removing

its bolt.

INSTALLATION

1. Apply A/T fluid to the input shaft speed sensor O-ring.

2. Install the inpu t shaft speed se nsor (1) to the A/ T case

and tighten the bolt to specified torque.

3. Connect input shaft speed sensor connector (2) to

input shaft speed sensor (1).

4. Connect the negative cable to the battery.

3.7 THROTTLE POSITION SENSOR

INSPECTION

Check the throttle position sensor, refer to Section 6E1,

2.3 ELECTRONIC CONTROL SYSTEM.

3.8 ENGINE COOLANT TEMPERATURE SENSOR

INSPECTION

Check engine cool ant temperature sensor refer to

Section 6E1, 2.3 ELECTRONIC CONTROL SYSTEM.

INPUT SHAFT SPEED SENSOR

RESISTANCE 560 - 690

Ω

@ 20°C

INPUT SHAFT SENSOR BOLT (a)

TORQUE SPECIFICATION 5.5 Nm

3.9 O/D OFF SWITCH

INSPECTION

1. Remove console box.

2. Disconne ct the O /D O FF sw itch connecto r (1) fr om th e

O/D switch (2).

3. Check the conti nuity between the O /D OFF switch ter-

minals.

3.10 SOLENOID VALVES (SHIFT SOLENOID VALVES, TCC SOLENOID VALVE AND

TIMING SOLENOID VALVE)

REMOVAL

1. Disconnect the negative cable at the battery.

2. Raise the vehicle on a hoist.

3. Remove the drain plug and drain A/T fluid.

4. Install the drain plug.

5. Remove the A/T oil pan (1) and oil pan gasket (2).

6. Remove the oil strainer assembly (3).

O/D off switch HELD IN RELEASED

Continuity Continuity No continuity

A/T FLUID DRAIN PLUG

SPECIFIED TORQUE 17 Nm

7. Remove the transmission fluid temperature sensor (1)

from the sensor clamp.

8. Disconnect the solenoid connectors (2).

9. Remove the TCC solenoid valve (1), shift solenoid

valve-A (No.1) (2), shift solenoid valve-B (No.2) (3) and

timing solenoid valve (4) by removing their bolts.

INSPECTION

Resistance Check

Shift solenoid valves, Timing solenoid valve and

Transmission Resistance at 20°C.

SHIFT SOLENOID VALVE RESISTANCE

STANDARD 11 - 15

Ω

@ 20°C

OPERATION CHECK

Shift Solenoid Valve-A (No.1), -B (No.2) And TCC

Solenoid Valve (Denso Type)

CAUTION: To avoid damage when blowing air into the

solenoid valve, do not insert the air gun against the

strainer on the inlet of the solenoid valve too deeply.

• C heck that th e sole noid v alve (1 ) actuat es with a click-

ing sound when battery voltage is applied.

• When t h e so le noi d va lv e ( 1) i s c on n ec t ed to t h e ba tt er y

(2), confirm that the solenoid valve is in a closed condi-

tion by blowing air (50 – 200 kpa) into the solenoid

valve as shown in the figure.

• When the solenoid valve (1) is not connected to the

battery (2), confirm that the solenoid valve is in an

open condition by blowing air (50 – 200 kpa) into the

solenoid valve as shown in the figure.

NOTE: Complete air test as described above to prevent

misdiagnosis as return spring is not installed in solenoid

valve.

Shift Solenoid Valve-A (No.1), -B (No.2) And TCC

Solenoid Valve (Aisin Type)

CAUTION: To avoid damage when blowing air into the

solenoid valve, do not insert the air gun against the

strainer on the inlet of the solenoid valve too deeply.

• C heck that th e sole noid v alve (1 ) actuat es with a click-

ing sound when battery voltage is applied.

• When t h e so le noi d va lv e ( 1) i s c on n ec t ed to t h e ba tt er y

(2), confirm that the solenoid valve is in a closed condi-

tion by blowing air (50 – 200 kpa) into the solenoid

valve as shown in the figure.

• When the solenoid valve (1) is not connected to the

battery (2), confirm that the solenoid valve is in an

open condition by blowing air (50 – 200 kpa) into the

solenoid valve as shown in the figure.

NOTE: Complete air test as described above to prevent

misdiagnosis as return spring is not installed in the solenoid

valve.

TIMING SOLENOID VALVE (BOTH DENSO AND AISIN TYPE)

CAUTION: To avoid damage when blowing air into the

solenoid valve, do not insert the air gun against the

strainer on the inlet of the solenoid valve too deeply.

• Check that solenoid valve (1) actuate with a clicking

sound when battery voltage is applied.

• Wh en the timing sol enoid valve ( 1) is conne cted to the

battery (2), confirm that the timing solenoid valve is in

an open condition by blowing air (50 – 200 kpa) into

the solenoid valve as shown in the figure.

• Wh en the timing sol enoid va lve ( 1) is not conn ected to

the battery (2), confirm that the timing solenoid valve is

in a closed condition by blowing ai r (50 – 200 kpa) into

the solenoid valve as shown in the figure.

NOTE: Complete air test as described above to prevent

misdiagnosis as return spring is not installed in the solenoid

valve.

INSTALLATION

1. Install the shift solenoid valve-A (No.1) (1), shift

solenoid valve-B (No.2) (2), TCC solenoid valve (3)

and the timing solenoid valve (4).

SOLENOID VALVE BOLTS (a)

TORQUE SPECIFICATION 11 Nm

2. Connect the solenoid connectors identifying their

installation positions by wire colour.

3. Install the transmission flu id temperature sensor (5) to

the sensor clamp.

4. Install the oil strainer assembly (1).

5. Install new oil pan gasket (1) and oil pan (2).

Solenoid connector Wire colour

Shift solenoid valve-A (No.1) (2) White

Shift solenoid valve-B (No.2) (3) Black

Timing solenoid valve (1) Yellow

TCC solenoid valve (4) Light Green

OIL STRAINER BOLTS (a)

TORQUE SPECIFICATION 10 Nm

OIL PAN BOLTS (b)

TORQUE SPECIFICATION 7.0 Nm

3.11 PRESSURE CONTROL SOLE NOID VALVE

REMOVAL

1. Disconnect the negative cable at the battery.

2. Raise the vehicle on a hoist.

3. Remove the drain plug and drain the A/T fluid.

4. Install the drain plug.

5. Remove the A/T oil pan (1) and the oil pan gasket (2).

6. Remove the oil strainer assembly (3).

7. Remove the transmission fluid temperature sensor (1)

from the sensor clamp.

8. Disconnect the solenoid connectors (2).

9. Remove the valve body assembly, refer to

4.5 UNIT DISASSEMBLY in this Section.

10. Remove the pressure control solenoid valve, refer to

VALVE BODY in 4.5 DIFFERENTIAL ASSEMBLY in

this Section.

A/T FLUID DRAIN PLUG

TORQUE SPECIFICATION 17 Nm

INSPECTION

Resistance Check

Measur e th e res i stance be twee n the press ur e c on tro l so le-

noid valve (1) terminals.

Operati on Check

Check the pressure con trol solenoid v alve operatio n in the

following manner:

[Using regulated DC power supply]

1. Connect the pressure control solenoid valve (1) to a

regulated DC power supply (2) as shown in the figure.

2. Turn the regulated DC power supply switch ON,

increase the voltage of the power supply keeping the

current within 1.0 A.

3. Check for gradual movement of valve (3) in the

direction of arrow “A” as the voltage is increased.

4. Check for movement of valve (3) in the direction of

arrow “B” as the voltage is decreased.

5. Turn the power supply switch OFF.

CAUTION: Do not pass a current of 1.0 A or more

through the pressure control solenoid or it may burn

out.

[Not using regulated DC power supply]

6. Connect the pressure control solenoid valve (1) to a

battery (2) with a 8 – 10 W bulb (4) connected as

shown in the figure.

7. Check for movement of valve (3) in the direction of

arrow “A”.

8. Disconnect the pressure control solenoid valve (1)

from the battery (2) and check for movement of valve

(3) in the direction of arrow “B” as shown in the figure.

CAUTION: Connect an 8 – 10 W bulb as shown or the

pressure contr ol solenoid valve may burn out.

PRESSURE CONTROL SOLENOID

VALVE RESISTANCE STANDARD 5.0 - 5.6

Ω

@ 20°C

INSTALLATION

Reverse removal procedure to install the pressure control

solenoid valve and the valve body noting the following

points:

• Fo r detail o f the pressure contro l solen oid va lve ins tal-

lation, refer to VALVE BODY in

4.5 DIFFERENTIAL ASSEMBLY in this Section.

• For details of the valve body installation, refer to

4.6 UNIT ASSEMBLY in this Section.

• For details of installing the wire harness for the sole-

noid valves and sensor, refer to 4.6 UNIT ASSEMBLY

in this Sectio n. Use new O- rin gs .

• Fo r details of the A/T oil pan a nd oil strain er assembly

installation, refer to 4.6 UNIT ASSEMBLY in this

Section. Use a new oil pan gasket.

• Replenish the A/T fluid and check the fluid level

according to procedure described in FLUID CHANGE

in 3.1 MAINTENANCE SERVICE in this Section.

• Check for fluid leaks after A/T warms up.

3.12 TRANSMIS SION CONTROL MODULE (TCM)

CAUTION:

• The TCM and ECM consists of precision parts,

therefore when handling, take care not to expose it

to excessive shock.

• When replacing the TCM with a used one, all the

learned contents, which have been stored in the

TCM memory by executing learning control, should

be initialised after replacement.

REMOVAL

1. Disconnect the negative cable at the battery.

2. Disable the air bag system. Refer to DISABLING AIR

BAG SY STE M in Section 10B, 3.1 SERVICE

PRECAUTIONS.

3. Disconnect connectors (1) from the TCM.

4. Remove the nuts (2) securing the TCM (3) and remove

TCM.

INSTALLATION

Reverse removal procedure noting the following:

• Connect the TCM connectors securely.

• Enable the air bag system after the TCM has been

refitted. Refer to ENABLING AIR BAG SYSTEM in

Section 10B, 3.1 SERVICE PRECAUTIONS.

LEARNING CONTROL INITIALISATION

1. Remove the glove box (1) from the instrument panel.

2. Using a service wire, connect the diagnosis switch

terminal (1) and the ground terminal (2) of the

diagno sis connecto r No.2 (3 ).

3. Turn the ignition switch ON leaving the engine OFF.

4. Confirm that the O/D OFF switch is OFF.

5. Shift the selector lever to L range.

6. With the br ake pedal and acceler ator peda l depresse d

fully, turn the O/D OFF switch ON and OFF 5 times

within 10 seconds to complete memory initialisation.

NOTE: When initialisation is achieved, the O/D OFF lamp

does no t light or flash u nless the diagnosi s swit ch termina l

is disconnected from the ground terminal of the diagnosis

connector No. 2. If initialisation has failed, repeat the initial-

ising procedure.

BRIEF LEARNING

This method is useful when the learned condition for the automat ic transaxle needs to be initialised quickly.

For example, when the shift shock in shifting 4th gear to 3rd becomes worse after replacing the TCM.

1. Turn the ignition switch ON, and confirm that the O/D OFF switch is OFF (the O/D OFF light in the

combination meter does not light).

2. Start the engine and raise the transaxle fluid temperature to normal operating temperature.

3. Start the vehicle and repeat the kickdown of 4th gear to 3rd gear, 10 times in each of the vehicle speed

ranges shown below.

• 27 – 35 km/h

• 35 – 58 km/h

• 58 – 81 km/h

• 81 – 104 km/h

• 104 – 126 km/h

4. Refer to 2.4 AUTOMATIC GEAR SHIFT DIAGRAM in this Section, perform upshifting of 3rd gear to 4 th

gear, 10 times in each of the throttle opening ranges shown below.

• 0 - 20 %

• 20 - 40 %

• 40 - 60 %

• 60 - 80 % (if necessary)

• 80 -100 % (if necessary)

5. At D range, perform upshifting 10 times in each of the vehicle speed ranges shown below.

• 20 - 55 km/h

• 55 - 70 km/h

• 70 - 90 km/h

• 90 - 125 km/h (if necessary)

• 125 - km/h (if necessary)

3.13 A/T RELAY

INSPECTION

1. Disconnect the negative cable at the battery.

2. Remove the A/T relay (2) from the fuse and relay box

(1).

3. Check that there is no continuity between terminal C

and D.

If the continuity is indicated, replace the A/T relay.

4. Connect the battery positive (+) terminal to terminal A

of the A/T relay and the battery negative (–) terminal to

the terminal “B” of the A/T relay.

Check the continuity between terminal C and D of the

A/T relay.

If continuity is not indicated, replace the A/T relay.

“D”

“B”

“A”“C”

3.14 TRANSMISSION FLUID TEMPERATURE SENSOR

INSPECTION

1. Disconnect the negative cable at the battery.

2. Raise the vehicle on a hoist.

3. When the engine is cool, remove the drain plug and

drain the A/T fluid.

4. Install the drain plug.

5. Remove the A/T oil pan.

6. Remove the oil strainer assembly.

7. Remove the valve body assembly, refer to

4.3 UNIT DISASSEMBLY in this Section.

CAUTION: When removing the valve body harness

from the transaxle case, take care not to damage the

transmission fluid temperature sensor at the narrow

exit of the case.

Careless sensor treatment may cause sensor

malfunction.

8. Remove the valve body harness bolt and remove the

valve body harness.

9. Heat the transmission fluid temperature sensor (2).

Check the resistance between the terminals of the

valve body harness connector (1). Ensure its resis-

tance decreases as its temperature increases.

Transmission fluid temperature sensor resistance

Temperature Resistance

10°C 5.8 – 7.1 kΩ

110°C 231 – 263 Ω

145°C 105 – 117 Ω

INSTALLATION

Reverse removal procedure to install the solenoid wire har-

ness and valve body noting the following points:

• For details of the valve body and their connectors

installation, refer to 4.6 UNIT ASSEMBLY in this

Section.

• For details of the A/T oil pan installation, refer to

4.6 UNIT ASSEMBLY in this Section. Use a new oil

pan gasket.

• Tighten the valve body harness connector bolt to spec-

ified torque.

• Repl enish the A/T fluid a nd check the fluid level , refer

to FLUID CHANGE in 3.1 MAINTENANCE SERVICE

in this Sectio n.

• Chec k fo r flu id le aks after the A /T ha s reac hed o perat-

ing temperature.

VALVE BODY HARNESS CONNECTOR

BOLT (a)

TORQUE SPECIFICATION 5.5 Nm

3.15 DIFFERENTIAL SIDE OIL SEAL

REPLACEMENT

1. Raise the vehicle on a hoist and drain the A/T fluid.

2. Remove the drive shaft joints from differential gear on

the transaxle, refer to Section 4A FRONT DRIVE

SHAFTS.

It is not n ecessary to remo ve the drive sha fts from the

steering knuckles to remove the differential side oil

seal.

3. Remove the transfer, refer to Section 7D TRANSFER.

4. Remove the differential side oil seal (1) using a screw

driver or similar.

5. Apply grease to the new differential side oil seal lips.

Lithium grease

6. Install the new differential side oil seals (1) using

special tools 09944-88220 (C) and 09924-74510 (D).

[A] - Right side

[B] - Left side

7. Install the transfer, refer to Section 7D TRANSFER.

8. Install the drive shaft, refer to Section 4A FRONT

DRIVE SHAFTS.

9. Replenish the A/T fluid, refer to FLUID CHANGE in

3.1 MAINTENANCE SERVICE in this Section.

DIFFERENTIAL SIDE OIL SEAL

INSTALLING DEPTH RIGHT SIDE (a)

LEFT SIDE (b) 2.6 - 3.6 mm

3.8 - 4.8 mm

3.16 AUTOMATIC TRANSAXLE ASSEMBLY

CAUTION: When the transaxle has been replaced, learned contents, which have been stored in the

TCM memory by executing learning control, should be initialised, refer to LEARNING CONTROL

INITIALISATION in 3.12 TCM in this Section.

Neglecting this initialisation may cause excessive shift shock.

COMPONENTS

Legend

1. Drive plate 3. Drive plate to torque 6. Transaxle and engine

2. Drive plate bolt

: Apply sealant Three Bond

No. 1216B to thread.

converter bolt fastening bolt

4. Torque converter 7. Transaxle and engine

5. Transaxle housing lower fastening nut

plate Tightening torque

REMOVAL

1. Remove the transaxle with the engine. Refer to

Section 6A1 ENGINE MECHANICAL.

2. Remove transfer from, refer to

Section 7D TRAN SFE R .

3. Remove the transaxle housing lower plate (1).

4. Remove the drive plate to torque converter bolts.

To lock the drive plate (1), Insert flat head rod or similar

(2) into the drive plate ring gear as shown in the figure.

1. Remove the starting motor, refer to

Section 6G CRAN KIN G SY ST EM.

WARNING: Keep the transaxle (with torque converter)

horizontal or facing up during repairs. Should it be

tilted downwards, the torque converter may fall off

causing personal injury.

NOTE: When removing the transaxle from the engine,

move it parallel with the crankshaft and take care not to

apply excessive force to the drive plate and torque con-

verter.

2. Remove the bolts and nut fastening the engine and

transaxle, then remove the transaxle from the engine.

INSTALLATION

1. Make sure that the torque converter is installed

correctly to the transaxle.

Refer to 4.6 UNIT ASSEMBLY in this Section.

WARNING: Keep the transaxle (with torque converter)

horizontal or facing up during repairs. Should it be

tilted downwards, the torque converter may fall off

causing personal injury.

2. Attach the transaxle to the engine.

3. Tighten the drive plate to torque converter bolts.

Align the bolt holes of the drive plate and torque

converter then tighten bolts through torque converter

housing lower plate opening.

Lock the drive plate (1) by inserting a flat head rod or

similar (2) into the drive plate gear.

4. Install the transaxle housing lower plate (1).

5. Install the starter motor, refer to

Section 6G CRAN KIN G SY ST EM.

6. Install the transfer referring to Section 7D TRANSFER.

7. Install the engine with the transaxle assembly to the

vehicle. Refer to Section 6A1 ENGINE MECHANICAL.

TRANSAXLE & ENGINE FASTENING

BOLTS & NUT (a)

TORQUE SPECIFICATION 85 Nm

DRIVE PLATE TO TORQUE CON-

VERTER BOLTS (a) 19 Nm

TRANSAXLE HOUSING LOWER PLATE

BOLTS (a)

TORQUE SPECIFICATION 10 Nm

STARTER MOTOR BOLT & NUT

TORQUE SPECIFICATION 50 Nm

4. UNIT REPAIR

When repairing the automatic transaxle, it is necessary to conduct an on-vehicle test to help determine the

cause of any problems.

It can then be determined if an A/T overhaul is required. If the transaxle is disassembled without a preliminary

on-vehicle test, the cause of the problem may not be clear resulting in repairs that are not necessary.

4.1 PRECAUTIONS

As the automatic transaxle consists of precision components, the following cautions should be strictly

observed when handling parts in disassembly and reassembly.

• Disassembling the valve body assembly is PROHIBITED except for some minor parts. To confirm which

parts may be disassembled, refer to VALVE BODY in 4.5 DIFFERENTIAL ASSEMBLY in this Section.

• When the com ponent parts of the forward clutch and /or the O/D and 2nd coast br ake (namely the clutc h

disc, brake disc, retaining plate and/or separator plate) have been replaced, al learned contents, which

have been stored in the TCM memory by executing learning control, should be initialised, refer to

3.12 TRANSMISSION CONTROL MODULE - LEARNING CONTROL INITIALISATION in this Section.

• Clean the transaxle to prevent dirt from entering the transaxle during removal and installation.

• Select a clean place free from dust and dirt for overhauling.

• Place a rubber mat on the work bench to protect parts from damage.

• Work gloves or shop cloth should not be used for cleaning. (Use a nylon cloth or a paper towel.)

• When separating the ca se jo in t, do no t pry wit h a sc rewdri ver o r simi lar b ut tap lig htly with a plas tic h am-

mer.

• Wash the disas s emb led parts in ATF (Au t om atic Transaxle Fl uid) o r ke rosene (taking care n ot t o a ll ow A /

T fluid or kerosene to splash on your face, etc.) and confirm that all fluid passages are not clogged by

blowing compressed air through them. Use kerosene to wash the discs, resin washers and rubber parts.

• Replace all gaskets, oil seals and O-rings with a new ones.

• Apply A/T fluid to sliding or rotating parts before reassembly.

• New discs should be soaked in A/T fluid for at least 2 hours before use.

4.2 PART INSPECTION AND CORRECTION TABLE

4.3 UNIT DISASSEMBLY

CAUTION:

• Thoroughly clean the transaxle exterior before overhauling it.

• Keep the working table, tools and hands clean when overhauling the A/T assembly.

• Take care when handling aluminum parts to avoid damage.

• Do not expose removed parts to dust. Always keep them clean.

Part Inspect for Correction

Casted part, machined part Small flaw, burr Remove with oil stone.

Deep or grooved flaw Replace part.

Clogged fluid passage Clean with air or wire.

Flaw on installing surface, residual gasket Remove with oil stone or replace

part.

Crack Replace part.

Bearing Uneven rotation Replace.

Streak, pitting, flaw, crack Replace.

Bushing, thrust washer Flaw, burr, wear, burning Replace.

Oil seal, gasket Flawed or hardened seal ring Replace.

Worn seal ring on its periphery or side Replace.

Piston seal ring, oil seal, gasket, etc. Replace.

Gear Flaw, burr Replace.

Worn gear tooth Replace.

Splined part Burr, flaw, torsion Correct with oil stone or replace.

Snap ring Wear, flaw, distortion Replace.

No interference Replace.

Thread Burr Replace.

Damage Replace.

Spring Settling, sign of burning Replace.

Friction plate Wear, burning, distortion, damaged claw Replace.

Separator plate, retaining plate Wear , burning, distortion, damaged claw Replace.

Sealing surface (where lip

contacts) Flaw, rough surface, stepped wear, for-

eign material Replace.

COMPONENTS

NOTE: The oil pump assembly, direct clutch assembly, forward and reverse clutch assembly , 2nd brake piston

assembly, O/D and 2nd coast brake piston and return spring, differential assembly, countershaft assembly

and valve body assembly are not shown in figure below. For details of these components, refer to

4.4 DISASSEMBLY/ASSEMBLY OF SUBASSEMBLY in this Section.

Legend

1. Torque converter 38. Cooler check valve 67. 2nd brak e separator

plate

2. Torque converte r housing

: Apply se alant Three Bond

No. 1216B to m ating

surface to transaxle case.

39. Spring

40. Transaxle case plug 68. 2nd brake return spring

subassembly

41. Fluid filler tube

42. Fluid level gauge 69. Front sun gear thrust

bearing race

3. Oil strain er assem bly

: Replace oil strainer

when overhauling.

43. Fluid cooler inlet pipe

44. Fluid cooler outlet pipe 70. Front planetary sun gear

45. 2nd brak e gas ket 71. Plan et ary gea r thrust

bearing

4. Parking lock pawl shaft 46. Brake drum gasket

5. Parking lock pawl 47. Fluid outlet union 72. One-way clutch No.1

assembly

6. Parking lock pawl return

spring 48. Reduction drive gear

nut

: After tightening nut so

as rotational torque of

reduction drive gear to

be in specified value,

caulk nut securely.

73. Rear planetary sun gear

subassembly

7. Parking lock pawl rod

8. Parking lock pawl bracket 74. Rear sun gear thrust

bearing race

9. Manual dete nt spring

10. Manual valve lever 75. Rear sun gear thrust

bearing

11. Manual valve lever pin

12. Manual shift shaft 49. Reduction drive gear 76. Forward clutch hub

13. Manual shift shaft oil seal

: Apply Lithium grease to oil

seal lip.

50. Planetary ring gear

subassembly 77. Intermediate shaft thrust

bearing race

51. Breather hose 78. Intermediate sh aft thrust

bearing

14. Differential sid e oil se al

: Apply Lithium grease to oil

seal lip.

52. Breather union

53. Input shaft speed

sensor 79. 2nd brake piston

snap ring

15. Torque converter

housing plug 54. Valve body harness 80. O/D and 2nd coast brake

retaining plate snap ring

55. 1st and reverse brake

piston

16. Lubrication LH tube 81. O/D and 2nd coast brake

reta ini ng pla te

17. Lubrica tion RH tube 56. O-ring

18. Fluid reservoir RH plate 57. 1st and reverse brake

return spring

subassembly

82. O/D and 2nd coast brake

disc

19. Input shaft front thrust

bearing 83. O/D and 2nd coast brake

separator pl ate

20. Input shaft rear thrust

bearing 58. 1st and reverse brake

disc 84. O/D and 2nd coast brake

rear plate

21. Input shaft rear thrust

bearing race 59. 1st and reverse brake

sepa rator plate 85. Rear cover seal ring

22. Direct clutch hub 60. 1st and reverse brake

retaining plate 86. Reverse clutch drum

thrust bearing

23. Lubrication tube clamp

24. Fluid reservoir LH plate 61. 1st and reve rse brake

snap ring 87. Rear cover plug

25. Governor apply

No.2 gasket 88. Transaxle rear cover

Apply sealant Th ree Bond

No. 1216B to

mating surface.

62. Planetary gear

assembly

26. Automatic transaxle case

27. Accumulator piston

O-ring 63. Planetary carrier thrust

washer

: Apply Lithium grease to

slide con tact face.

89. Harness bracket

90. Select cable clam p

28. Accumulator spring 91. Governor apply No.1

gasket

29. C2 accumulator piston

30. C1 accumulator piston 92. O utput shaft speed

sensor (VSS)

31. B1 accumulator piston 64. One-way clutch No.2

assembly

32. Oil pan gasket 93. O ne-way clutch outer

race retainer

33. Oil pan 65. 2nd brake ret a ining

plate

34. A/T fluid drain plug Do not reuse.

35. Manual select leve r

36. Lock washer 66. 2nd brake disc

plate Apply automatic

transa xle fluid.

37. Transm is si on rang e

sensor

DISASSEMBLY

CAUTION: When removing the torque converter keep it

as straight (level) as possible to avoid damaging the oil

seal lip.

1. Remove the torque converter (1).

2. Remove the engine mount LH bracket (1).

3. Remove the manual select lever (1).

4. Unstake the lock wa sher (1) , then r emove t he lock nut

(2) and the lock washer (1).

5. Remove the transmission range sensor (1).

6. Remove the input shaft speed sensor (1) and the

output shaft speed sensor (VSS) (2).

7. Remove the harness bracket (3) and the select cable

clamp (4).

8. Remove the fluid cooler pipes (1) and the fluid outlet

union (2).

9. Remove the fluid level gauge (3) and the fluid filler tube

(4).

NOTE:

• When removing the oil pan, do not turn the transaxle

over as this will contaminate the valve body with for-

eign matter from the bottom of the oil pan.

• Wh en removing the oil pan, tap around i t lightly wi th a

plastic ha mme r. Do not p ry it o ff usin g a s crewd r iver or

similar.

10. Remove the oil pan (1) and the oil pan gasket (2).

11. Remove the oil strainer assembly (1).

12. Disconnect the connectors from the solenoid valves,

and transmission fluid temperature sensor (1).

CAUTION: Do not let the manual valve fall off when

removing the valve body assembly.

NOTE: There are fi ve kinds of bo lts (bolts A(1), B(2) , C(3),

D(4), and E(5)) fixing the valve body assembly.

13. Remove the valve body assembly bolts.

14. Remove the manual valve rod (1) from the manual

valve lever (2), then remove the valve body assembly

(3).

CAUTION: When removing the valve body harness (1)

from the transaxle case, take care not to damage the

transmission fluid tempe rature sensor (2 ) at the narr ow

exit of the case.

Careless s ensor tr eatment may cause se nsor malfun c-

tion.

15. Remove the valve body harness (1).

16. Remove the governor apply No.1 gasket (1).

17. Remove the cooler check valve (1) and spring (2).

NOTE: Do not push the accumulator pistons in before

removing them or compressed fluid in the accumulator may

spew out of the hole.

18. Remove the accumul ato r pis ton s and sp rings .

To remove C2 (1), C1 (2) and B1 (3) accumulator

pistons and springs, cover with rag then force low-

pressu re comp ressed ai r into hole (4 ) as shown in the

figure and pop each piston into rag.

19. Remove the transaxle case plug (1).

20. Remove the torque converter housing bolts.

21. Remove the torque converter housing (1) by tapping

around it lightly with a plastic hammer.

22. Remove the breather hose (1).

23. Remove the breather union (2).

24. Measure the input shaft thrust play.

Apply a dial gaug e, specia l tools 09900-2 0607 (A) and

09900-20701 (B), onto the input shaft end (1) and

measure the thrust play of the input shaft.

When the input shaft thrust play is out of specification,

select an input shaft front thrust bearing with the correct

thickness from the list below and replace.

25. Remove the oil pump assembly (1).

26. Remove the direct clutch assembly (1).

INPUT SHAFT THRUST PLAY 0.3 - 0.9 mm

AVAIL.ABLE INPUT SHAFT FRONT

THRUST BEARING THICNESS 0.8 mm

1.4 mm

27. Remove the input shaft front thrust bearing (1).

NOTE: If the inp ut sha ft front thrus t bearing is no t in pl ace,

it may have been removed with the oil pump assembly

28. Remove the i nput shaft rear thrust bea ring (1) and the

thrust bearing race (2).

NOTE: If the input shaft rear thrust bearing is not in place, it

may have been removed with the direct clutch assembly.

29. Remove the direct clutch hub (1).

30. Remove the differential assembly (1) and the counter

shaft assembly (2).

31. Remove the governor apply No.2 gasket (1).

32. Remove the fluid reservoir LH plate (1).

33. Turn the transaxle over and remove the rear cover

assembly (1).

34. Remove the reverse clutch drum thrust bearing (1).

NOTE: If the reverse clutch drum thrust bearing is not in

place, it may have been removed with the rear cover

assembly.

35. Remove the 2nd brake gasket (1).

36. Measure the O/D and 2nd coast brake piston stroke.

• Measure dim ension “a” from mating the surface of the

transaxle case to the O/D and 2nd coast brake rear

plate (1) using a straightedge and a micrometer cali-

per.

• Measure dimension “b” from the O/D and 2nd coast

brake piston (2) to the rear cover assembly mating sur-

face using a straightedge and a micrometer caliper.

• Cal cul ate the piston str oke fr om the mea su red val ue of

dimensions “a” and “b”.

• Piston stroke = “a” – “b”

If the piston stroke exceeds the specification above,

inspect and replace plates and discs.

CAUTION: When the component parts of the O/D and

2nd coast brake (namely brake disc, retaining plate,

separator plate and/or rear plate) have been replaced,

learned contents, which have been stored in the TCM

memory by executing l ear ning c ontrol , should be initi-

alised, refer to LEARNING CONTROL INITIALISATION

in 3.12 TRANSMISSION CONTROL MODULE in this

Section.

Neglectin g this init ialis atio n may ca u se ex ces sive shift

shock.

37. Remove the forward and reverse clutch assembly (1).

38. Remove the intermediate shaft thrust bearing front

race (1), thrust bearing (2) and rear race (3) from the

forward and reverse clutch assembly (4).

NOTE: If the intermedia te sh aft thrust beari ng and /or ra ces

are not in place on the forward and reverse clutch assem-

bly, they may have remained in the transaxle.

O/D & 2ND COAST BRAKE PISTON

STROKE STANDARD 0.65 - 1.05 mm

39. Remove the O/D and 2nd coast brake rear plate (1),

discs (2), separator plate (3) and retaining plate (4).

40. Remove the forward clutch hub (1).

41. Remove the rear sun gear thrust bearing (1) from the

forward clutch hub (2).

NOTE: If the rear sun ge ar thr ust beari ng is not in place on

the forward clutch hub, it may have remained in the tran-

saxle

42. Remove the rear sun gear thrust bearing race (1).

43. Remove the rear planetary sun gear subassembly (1)

and the one-way clutch No.1 assembly (2).

44. Remove the planetary gear thrust bearing (1).

NOTE: If the planetary gear thrust bearing is not in place

on the one-way clutch No.1 assembly, it may have

remained in the transaxle.

45. Remove the one-way clutch No.1 assembly (2) from

the rear planetary sun gear subassembly (3).

46. Remove the planetary carrier thrust washer (1).

47. Remove the O/D and 2nd coast brake retaining plate

snap ring (1).

48. Remove the front planetary sun gear (1).

49. Remove the front sun gear thrust bearing race (2) from

the front planetary sun gear (1).

50. Before disassembling the 2nd brake piston assembly

(4), check the 2nd brake piston stroke by measuring

the clearance between the 2nd brake separator plate

(1) and the piston (2) with a feeler gauge (3).

If the clearance (piston stroke) is out of specification,

replace the brake discs and plates with new ones.

CAUTION: When the component parts of the 2nd brake

(namely the brake disc, retaining plate and/or separa-

tor plate) have been replaced, all learned contents,

which have been stored in the TCM memory by execut-

ing learning control, should be initialised, refer to

3.12 TRANSMISSION CONTROL MODULE - LEARNING

CONTROL INITIALISATION in this Section.

Neglectin g this init ialis atio n may ca u se ex ces sive shift

shock.

CAUTION: Do not press 2nd brake piston assembly in

more than 0.4 mm.

Excessiv e compressi on may cause d amage to th e pis-

ton assembly, return spring, plates and/or discs.

51. Using special tool 09926-96050 (A) and hydraulic

press, remove the 2nd brake piston snap ring (1).

52. Remove the 2nd brake piston assembly (1).

53. Remove the 2nd brake return spring subassembly (1).

2ND BRAKE PISTON STROKE (a) 0.40 - 1.25 mm

54. Remove the 2nd brake separator plates (1) discs (2)

and retaining plate (3).

55. Remove the brake drum gasket (1).

56. Remove the one-way clutch outer race retainer (1).

57. Check the one-way clutch No.2 as follows.

• Ens ure the pla netary carrier (1) rotates only in a coun-

terclockwise direction “A”, never in a clockwise

direction “B”.

• If the planetary carrier rotates both ways or does not

rotate either way, the one-way clutch No.2 assembly

will need to be replaced.

58. Remove the one-way clutch No.2 assembly (1).

59. Remove the planetary gear assembly (1).

60. Measure the 1st and reverse brake piston stroke

• Using special tools 09900-2607 (A), 09900-20701 (B)

and 09952-06020 (C), measure the 1st and reserve

brake piston stroke when compressed air (400 – 800

kPa) is blown through the oil hole (1).

If the piston stroke exceeds the specified value, disassem-

ble, inspect and replace discs and plates.

CAUTION: Do not press the 1st and reverse brake

return spring subassembly in more than 0.8 mm.

Excessive compression may cause damage to return

spring subassembly, discs, plates and/or piston.

61. Remove the s nap ring whil e the 1st and rev erse brake

piston return springs are compressed using special

tool 09926-97620 (A) and hydraulic press.

62. Remove the 1st and reverse brake retaining plate,

discs and separator plates.

63. Remove the 1st and reverse brake return spring sub-

assembly (1).

1ST & REVERSE BRAKE PISTON

STROKE STANDARD 0.79 - 1.49 mm

64. T urn the transaxle over and unstake the reduction drive

gear nut (1).

CAUTION:

• It is recommended that this operation should be

carried out on rubber mat to prevent damaging the

transaxle case.

• Never reuse a removed nut.

65. Secure the reduction drive gear (1) with the parking

lock pawl, then remove the reduction drive gear nut.

66. Using sp eci al too ls 09 913-8 4510 ( A), 09 923 -7821 0 ( B)

and hydraulic press, remove the planetary ring gear

subassembly (1).

CAUTION: Do not reuse the pla netary ring gear su bas-

sembly. To do so may cause damage to the planetary

gear unit and/or the reduction gears.

67. Remove the parking lock pawl shaft, the spring (2) and

parking lock pawl (1).

CAUTION: Screw 3 bolts into the reduction drive gear

evenly, or the reduction drive gear, bearing and tran-

saxle case may be damaged.

68. Screw 3 bolts (1 ) into th e redu cti on driv e gea r (2) the n,

remove the reduction drive gear (2).

69. Blowing compressed air from the oil hole (1) of the oil

pump, remove the 1st and reverse brake piston (2).

70. Remove the parking lock pawl bracket (1).

71. With a slotted screw driver, cut and unfold the manual

valve lever spacer (1) and proceed to remove the

manual valve lever spacer.

BOLT LENGTH

1 30 mm

72. Using a spring pin remover (3 mm diameter) and a

hammer, drive out the manual valve lever pin (1).

73. Remove the manual shift shaft (2).

74. Remove the parking lo ck pawl rod (2) f rom the ma nual

valve lever (1).

75. Remove the manual detent spring (1).

76. Remove the manual shift shaft oil seal (1).

INSPECTION

Brake Discs

Dry and inspect the brake discs for pitting, burn flaking, sig-

nificant wear , glazing, cracking, charring and chips or metal

particles imbedded in lining.

If the disc s sh ow any of the ab ove co nditions , replac ement

is required.

NOTE:

• If the disc lining is flaking or discoloured, replace all

discs.

• Before assembling new discs, soak them in A/T fluid

for at least two hours.

Brake Separator Plates And Retaining Plates

Dry the plates and check for discolouration. If the plate

surface is smooth and even colour smear is indicated,

the plate can be reused. If severe heat spot discoloura-

tion or surface scuffing is present, the plate must be

replaced.

Brake return spring subassembly

Meas u re th e bra k e re turn spri ng s .

NOTE:

• Do not apply excessive force when measuring spring

free length

• Perform measurement at several points.

Evidence of extreme heat or burning in the area of the

clutch may have caused the springs to take heat set and

would require their replacement.

One-way Clutch No.1 Assembly

1. Install the one-way clutch No.1 assembly (2) to the rear

planetary sun gear subassembly (1).

2. Securing the rear planetary sun gear subassembly,

ensure that the one-way clutch No.1 assembly rotates

in one directi on only.

If the one-way clutch rotates in both directions or it

does not ro tate in ei ther di rec tio n, r eplac e it wi th a new

one.

FREE LENGTH OF 1st & REVERSE

BRAKE RETURN SPRINGS (a) 21.71 mm

FREE LENGTH OF 2ND BRAKE

RETURN SPRINGS (a) 15.85 mm

“a”

4.4 DISASSEMBLY/ASSEMBLY OF SUBASSEMBLY

CAUTION:

• Keep component parts in groups of each subassembly and avoid intermingling them.

• Clean all parts with cleaning solvent thoroughly and air dry them.

• Use kerosene or automatic transaxle fluid as a cleaning solvent.

• Do not use wiping cloths or rags to clean or dry parts.

• All oil passages should be blown out and checked to make sure that they are not obstructed.

• Protect face and eyes from solvent spray while air blowing parts.

• Check the mating surface for irregularities. Remove any irregularities and repeat cleaning.

• Soak new clutch discs and brake discs in A/T fluid for at least 2 hours before assembly.

• Replace all gaskets and O-rings with new ones.

• Apply A/T fluid to all O-rings.

• When installing the seal ring, ensure it has not expanded excessively, been extruded or pinched.

• Replace the oil seals that are removed with new ones and apply grease to their lips.

• Before installing, apply A/T fluid to sliding, rolling and thrusting surface of all component parts.

After installation, check each part for correct operation.

• Always use torque wrench when tightening bolts.

OIL PUMP

Legend 1. Oil seal

: Apply Lithium grease to oil

seal li p.

4. Oil pump driven gear Apply automatic transaxle

fluid

5. Oil pump drive gear

6. Stator shaft assembly Tightening torque

2. O-ring 7. Oil pump subassembly

bolts Do not reuse.

3. Oil pump body

DISASSEMBLY

1. Remove the O-ring from the pump body.

2. Remove th e 8 o il pump s ubassembly bolts (1 ) and the

stator shaft assembly (2).

3. Remove th e oil seal (1) from th e pump body (2) using

special tool 09913-50121 (A).

INSPECTION

1. Check the body clearance of the driven gear.

Push the driven gear to one side of the body. Using a

feeler gauge, measure the clearance between the

driven gear (1) and the body (2).

If the clearance exceeds the standard value, replace

the oil pump assembly.

2. Check the tip clearance between the drive gear (2) and

the driven gear (1).

Using a feel er gauge, mea sure the cle arance betwee n

the drive and driven gear tips.

If the clearance exceeds the standard value, replace

the oil pump assembly.

CLEARANCE BETWEEN OIL PUMP

DRIVEN GEAR AND OIL PUMP BODY

STANDARD 0.1 - 0.17 mm

TIP CLEARANCE BETWEEN OIL PUMP

DRIVE GEAR AND OIL PUMP DRIVEN

GEAR STANDARD 0.07 - 0.15 mm

3. Check the side clearance of both gears.

Using a straightedge (1) and a feeler gauge (2),

measure the side clearance between the gears and

pump body.

If the clearance exceeds the standard value, replace

the oil pump assembly.

4. Using special tool 09900-20605 (A), measure the

stator shaft bush (1) bore.

If the stator shaft bush bore measure is out of specifi-

cation, replace the oil pump assembly with a new one.

5. Install the dir ect clutch ass embly (1) to the stator shaft

assembly (2), ensuring that the direct clutch assembly

turns smoothly.

If uneven rotation or noise are found in the oil pump

assembly, replace the oil pump assembly with a new

one. This check s hould also be done t o the input shaft

assembly. Replace input shaft assembly if necessary.

6. Using speci al tool 09 900-20 605 (A), measure oi l pump

body bush bore.

If the oil pump body bush bore measurement is out of spec-

ification, replace the oil pump assembly with a new one.

The torque converter also needs to be checked. Replace

the torque converter, if necessary.

SIDE CLEARANCE BETWEEN GEARS

AND OIL PUMP BODY STANDARD 0.02 - 0.05 mm

STATOR SHAFT BUSH BORE

STANDARD 18.4 24 - 18 .450 mm

OIL PUMP BODY BUSH BORE

STANDARD 38.113 - 38.138 mm

ASSEMBLY

1. Install a new oil seal (1) to the oil pump body (2).

Use special tool, 09913-85210 (A), and hammer to

install. Apply grease to the seal lip.

“A”: Lithium grease

2. Install the driven gear and drive gear to the oil pump

body after applying A/T fluid.

3. Install the stator shaft assembly to the oil pump body

and tighten the 8 pump subassembly bolts (1) to speci-

fication.

4. After apply ing A/T f luid to a new O-r ing, install it to the

oil pump body (1).

CAUTION: Do not damage the oil seal with slotted

screw driver.

5. Check the drive gear for smooth rotation using slotted

a screw driver (2).

OIL PUMP SUB-ASSEMBLY BOLTS (a)

TORQUE SPECIFICATION 10 Nm

DIRECT CLUTCH

Legend

CAUTION: When component parts of the forward

clutch (na mely clutch disc, retaining plate and /or se pa-

rator plate) have been replaced, learned contents,

which have been stored in the TCM memory by execut-

ing learning control, should be initialised, refer to

3.12 TRANSMISSION CONTROL MODULE - LEARNING

CONTROL INITIALISATION in this Section.

Neglectin g this init ialis atio n may ca u se ex ces sive shift

shock.

PRELIMINARY CHECK

1. Install the direct clutch assembly (1) to the oil pump

assembly (2), blow air (400 – 800 kPa) through the oil

hole (3) of the oil pump assembly with special tool,

09900-20607 (A) and 09900-207 0 (B) attached on the

upper s urface of the d irect clutch piston, and me asure

the piston stroke of the direct clutch.

If the piston stroke exceeds the specified value, disassem-

ble, inspect and replace inner parts.

1. Input shaft front thrust

bearing 6. Outer O-ring 11. Direct clutch retaining plate

7. Direct clutch return spring

subassembly 12. Plate snap ring

2. Input shaft seal ring Apply automatic transaxle

fluid.

3. Input shaft subassembly 8. Shaft snap ring

4. Inner O-ring 9. Direct clutch separator plate Do not reuse.

5. Direct clutch piston 10. Direct clutch disc

DIRECT CLUTCH PISTON STROKE 0.4 - 0.7 mm

DISASSEMBLY

1. Remove the plate snap ring (1), then remove the direct

clutch retaining plate, discs and separator plates.

CAUTION: Do not press direct clutch return spring

subassembly in more than 0.7 mm.

Excessive compression may cause damage to the

direct clutch return spring subassembly and/or piston.

2. Using special tool, 09926-98310 (A) and hydraulic

press, remove the shaft snap ring (1).

3. Remove the direct clutch return spring assembly (2).

4. To ass ist the remova l of the clutc h piston, use a finger

to block the oil hole (1), then apply compressed air

(400 – 800 kPa) to the opposite hole.

5. Remove the outer O-ring (1) from the direct clutch

piston (2).

6. Remove the inner O-ring (2) from the input shaft

assembly.

7. Remove the input shaft seal rings (1).

INSPECTION

Clutch Discs, Plates And Retaining Plate

Check that the sliding surfaces of discs, separator plates

and retaining plate are not worn hard or burnt. If necessary,

replace.

NOTE:

• If the disc lining is flaking or discoloured, replace all

discs.

• Before assembling new discs, soak them in A/T fluid

for at least two hours.

Direct Clutch Return Spring Subassembly

Measure the free length of direct clutch return spring.

NOTE:

• Do not apply excessive force when measuring the

spring free length.

• Perform the measurement at several points.

Direct Clutch Piston

Shake the direct clutch piston lightly and ensure that the

check ball (1) is not stuc k. Blow low-p ressure ai r (Max 100

kPa) to the check ball to ensure there is no air leakage.

ASSEMBLY

Reverse disassembly procedure for assembly, noting the

following points.

• Use a new seal ring and O- ring. Appl y A/T flui d before

installation.

FREE LENGTH OF DIRECT CLUTCH

RETURN SPRING (a) 36.04 mm

• Do not damage the direct clutch return spring subas-

sembly (1) and piston by pressing in the direct clutch

return spring subassembly more than 0.7 mm past its

original installation position Use special tool

09926098310 (A) to install the direct clutch return

spring sub as se mbl y.

• App ly A/ T fluid to the direc t clutch s eparator pl ates (4),

discs (3) and retaining plate (2).

• Install the direct clutch separator plates (4) discs (3)

retaining plate (2) and snap ring (1) to the input shaft

subassembly.

• Install the plate snap ring so that both ends are posi-

tioned correctly as shown in the figure.

[A] - Correct

[B] - Incorrect

• After assembly, measure the direct clutch (1) piston

stroke using special tools 09900-20607 (A) and 09900-

20701 (B) by blowing low-pressure air through the oil

pump assembly (2) oil hole (3).

When the piston stroke is out of specification, select the

direct clutch retaining plate with a suitable thickness from

the list below and replace it.

Available direct clutch retaining plate thickness

FORWARD AND REVERSE CLUTCH

Legend

DIRECT CLUTCH PISTON STROKE 0.4 - 0.7 mm

THICKNESS IDENTIFICATION MARK

3.0 mm 1

3.2 mm 2

3.4 mm 3

1. Forward clutch balancer 8. Inter mediate shaft seal ring 14. Forward clutch retaining plate

2. Forward clutch return sp ring

subassembly 9. Reverse clutch plate snap

ring 15. Forward clutch disc

16. Forward clutch separator

plate

3. Forward clutch piston 10. Reverse clutch retaining plate

4. Forward clutch piston O-ring 11. Reverse clutch separator

plate 17. Balancer snap ring

Apply automatic transaxle

fluid.

5. Forward clutch drum

6. Forward clutch drum O-ring 12. Reverse clutch disc

7. Intermediate shaft

subassembly 13. Forward clutch plate snap

ring Do not reuse.

CAUTION: When t he co mpo nent p ar ts of the for war d clu tch (cl utc h di sc, ret a in ing plate an d/o r separa-

tor plate ) have been replaced , learned contents, which have be en stored in t he TCM memory by exe-

cuting learning control, should be initialised, refer to 3.12 TRANSMISSION CONTROL - LEARNING

CONTROL INITIALISATION in this section.

Neglecting this initialisation may cause excessive shift shock

PRELIMINARY CHECK

1. Install the forward and reverse clutch assembly (1) to

the transaxle rear cover (2). Attach special tools

09900-20607 (A) and 09900-20701 (B) to the upper

surface of the reverse clutch retaining plate (3).

Blow compressed air (400 – 800 kPa) through the oil

hole (4) of the transaxle rear cover and measure the

reverse clutch piston stroke.

If the pist on strok e excee ds the sp ecified va lue, di sas-

semble, inspect and replace inner parts.

2) Blow compressed air (400 – 800 kPa) through the

oil hole (1) of the transaxle rear cover with special

tool 0 990 0- 20 607 ( A ), 0 990 0- 20 701 ( B ) an d 0 995 2-

06020 (C) attached on the upper surface of forward

clutch retaining plate, and measure the forward

clutch piston stroke.

If the piston stro ke exce eds th e speci fied va lue, dis-

assemble, inspect and replace inner parts.

DISASSEMBLY

1. Remove the reverse clutch plate snap ring (1) and

remove the reverse clutch retaining plate, discs and

separator plates from the intermediate shaft subas-

sembly.

2. Remove the forward clutch plate snap ring (1) and

remove the forward clutch retaining plate, discs and

separator plates from the forward clutch drum.

REVERSE CLUTCH PISTO N STROKE 0.86 - 1.26 mm

FORWARD CLUTCH PISTON STROKE 1.30 - 1.50 mm

CAUTION: Do not press the forward clutch return

spring subass embly in more than 1.5 mm.

Excessive compression may cause damage to the

return spring subassembly and/or balancer.

3. Remove the balancer snap ring using special tool

09926-97610 (A) and a hydraulic press.

4. Remove the forward clutch balancer (1).

5. Remove the forward clutch return spring subassembly

(1) from the intermediate shaft assembly (2).

Install the intermediate shaft subassembly (1) to the tran-

saxle rear cover (2). Apply compressed air (400 – 800 kPa)

to oil hole (3) of the transaxle rear cover to remove the for-

ward clutch piston (4).

6. Apply compressed air (400 – 800 kPa) to the oil hole

(1) of the transaxle rear cover to remove the forward

clutch drum (2).

7. Remove the forward clutch piston O-ring (1) from the

intermediate shaft subassembly (2).

8. Remove the forward clutch drum O-ring (1) from the

forward clutch drum (2).

9. Remove the intermediate shaft seal ring (1) from the

intermediate shaft subassembly (2).

INSPECTION

Clutch Discs, Separator Plates and Retaining Plate

Check that the sliding surfaces of discs, separator plates

and retaining plate are not worn hard or burnt. If necessary,

replace.

NOTE:

• If the disc lining is flaking or discoloured, replace all

discs.

• Before assembling new discs, soak them in A/T fluid

for at least two hours.

Forward Clutch Return Spring Subassembly

Measure free length of forward clutch return spring.

NOTE:

• Do not apply excessive force when measuring the

spring free leng th.

• Measure at several points.

Forward Clutch Piston Lip and Forward Clutch

Balancer Lip

Check ea ch lip for wear, d eformation, cuts, an d/or harden-

ing. If necessary, replace.

Forward Clutch Drum Lip

Check ea ch lip for wear, d eformation, cuts, an d/or harden-

ing. If necessary, replace.

ASSEMBLY

Reverse disassembly procedure for assembly, noting the

following points.

• Before assembling, apply A/T fluid to component parts.

• Replace O-rings and seal ring with new ones.

• Install the forward clutch return spring subassembly

and balancer using special tool 09926-97610.

Do not damage the forwa rd clutc h r etu rn spri ng s uba s-

sembly and balancer by pressing it in more than 1.5

mm passed its original installation position.

FREE LENGNTH OF FORWARD

CLUTCH RETURN SPRING 23.04 mm

• Apply A/T fluid to the forward clutch separator plates

(1), discs (2 ) and retainin g plate (3) .

• Ins tall the f orward c lutch s eparator p lates (1), d iscs (2)

and retaining plate (3), then the snap ring (4) to the for-

ward clutch drum.

• Install the forward clutch plate snap ring so both ends

are positioned in the correct location as shown in the

figure.

A - Correct

B - Incorrect

• Measure the forward clutch piston stroke in the same

manner as PRELIMINARY CHECK described previ-

ously using special tools 09900-20607 (A), 09900-

20701 (B) and 09952-06020 (C).

When the piston stroke is out of specification, select the

forward clutch retaining plate with the correct thickness

from the list below and replace it.

Available forward clutch retaining plate thickness

FORWARD CLUTCH PISTON STROKE 1.30 - 1.50 mm

THICKNESS IDENTIFICATION MARK

3.0 mm 1

3.1 mm 5

3.2 mm 2

3.3 mm 6

3.4 mm 3

3.5 mm 7

3.6 mm 4

• App ly A/ T f luid to the r ev ers e cl utch s epara tor pl ate ( 1)

discs (2) and retaining plate (3).

• Install the reverse clutch separator plate (1) discs (2)

retaining pl ate ( 3) and snap r i ng (4) to th e in ter me dia te

shaft subassembly.

• Install the reverse clutch plate snap ring so that its

ends are po siti oned in th e corre ct locati on as sh own in

the figure.

A - Correct

B - Incorrect

• Measure the reverse clutch piston stroke in the same

manner as PRELIMINARY CHECK described previ-

ously, us ing sp ecial tools 0990 0-206 07 (A) an d 09900-

20701 (B).

When the piston stroke is out of specification, select the

reverse clutch retaining plate with the correct thickness

from the list below and replace it.

Available reverse clutch retaining plate thickness

REVERSE CLUTCH PISTO N STROKE 0.86 - 1.26 mm

THICKNESS IDENTIFICATION MARK

3.0 mm 1

3.2 mm 2

3.4 mm 3

3.6 mm 4

2ND BRAKE PISTON

Legend

DISASSEMBLY

1. Apply compressed air (400 – 800 kPa) to the oil hole

(1) of the 2nd brake cylinder (3) to remove the 2nd

brake piston (2).

2. Remove the inner O-ring (1 ) and the oute r O-rin g (2).

1. 2nd brake cylinder 3. Inner O-ring Apply automatic transaxle

fluid.

2. 2nd brake piston 4. Outer O-ring Do not reuse.

ASSEMBLY

Reverse disassembly procedure for assembly, noting the

following points.

• Use new O- rings. Ap ply A/T f luid to t he O-rin gs before

installation.

• Apply A/T fluid to the 2nd brake piston (1) then install

onto the 2nd brake cylinder.

Do not damage the O-ring when installing the 2nd

brake piston.

TRANSAXLE REAR COVER ASSEMBLY (O/D AND 2ND COAST BRAKE PISTON)

Legend

1. Snap ring 5. O/D and 2nd coast brake

piston Apply automatic transaxle

fluid.

2. O/D and 2nd coast brake

return spring subassembly 6. Rear cover seal ring Do not reuse.

3. O/D and 2nd coast brake

piston front O-ring 7. Transaxle rear cover Tightening torque

8. Rear cover plug

4. O/D and 2nd coast brake

piston rear O-ring 9. Rear cover plug O-ring

DISASSEMBLY

CAUTION: Do not press the O/D and 2nd coast brake

return spring subassembly in more than 1.0 mm.

Excessiv e compressi on may cause d amage to th e O/D

and 2nd coast brake return spring subassembly and/or

piston.

1. Remove the snap ring from the transaxle rear cover (1)

using spe cial tools 099 26-96030 (A) and 09946-0671 0

(B) and hydraulic press.

2. Remove the O/D and 2nd coast brake return spring

assembly.

3. Apply compressed air (400 – 800 kPa) to the oil hole

(2) of the transaxle rear cover (1) to remove the O/D

and 2nd coast brake piston.

4. Remove the O/D and 2nd coast brake piston front O-

ring (1) and rear O-ring (2).

5. Remove the rear cover seal rings (1).

6. Remove the rear cover plugs (1).

INSPECTION

O/D and 2nd Coast Brake Return Spring Subass embly

Measure the free length of the O/D and 2nd coast blake

return spring.

NOTE:

• Do not apply excessive force when measuring the

spring free leng th.

• Measure at several points.

Transaxle Rear Cover Bush

7. Measure the transaxle rear cover bush bore using

special tool 09900-20605 (A).

If the m easure d trans axle re ar cove r bush bor e is out o f

specification, replace the transaxle rear cover with a

new one. During replacement, the intermediate shaft

subassembly also needs to be checked. Replace the

intermediate shaft subassembly, if necessary.

ASSEMBLY

Reverse disassembly procedure for assembly, noting the

following points.

• Use new seal rings and O-rings. Apply A/T fluid to seal

rings and O-rings before installation.

• Tighten the rear cover plugs to specified torque.

FREE LENGTH OF O/D AND 2ND

COAST BRAKE RETURN SPRING (a) 18.99 mm

TRANSAXLE REAR COVER BUSH

BORE STANDARD 13.94 - 14.00 mm

REAR COVER PLUGS

TORQUE SPECIFICATION 7.5 Nm

• Apply A/T fluid to the rear cover seal ring before install-

ing to the transax le rear cover. Tighten sea l ring 5 m m

(as shown) before installing.

• Do not open rear cover seal ring too wide to attach.

• Do not damage the O/D and 2nd coast brake return

spring s ubassembly an d piston by pre ssing in the O/ D

and 2nd coast brake return spring subassembly more

than 1.0 mm past its original installation.

Install the O/D and 2nd coast brake return spring sub-

assembly using special tools

09926-96030 (A) and

0994 6-06710 (B) to the transaxle rear co ver (1).

4.5 DIFFERENTIAL ASSEMBLY

Legend

1. Differential side RH bearing 5. Side bearing shim Apply automatic transaxle

fluid.

2. Output shaft speed sensor 6. Final gear bolt

(VSS) drive gear 7. Side bearing cup Tightening torque

3. Differential case subassembly 8. Differential side LH bearing Do not reuse.

4. Final gear

DISASSEMBLY

1. Remove the final gear bolts (1), and the final gear (2).

2. Remove the differential side RH bearing using special

tools 09926-37610 (A), 09926-37610-001 (B), 09926-

37610-003 (C) and 09926-37610-002 (D).

3. Remove the output shaft speed sensor (VSS) drive

gear (1) from the differential case subassembly.

4. Remove the differential side LH bearing using special

tools 09926-37610 (A), 09926-37610-001 (B), 09926-

37610-003 (C) and 09926-37610-002 (D).

INSPECTION

1. Hold the differential case subassembly in a soft jawed

vice and set special tools

09900-20607 (A) and

0990 0-20701 (B)

as shown.

2. Measure the differential gear thrust play.

3. If the thrust pla y is out of sp ecification, re place the dif-

ferential case subassembly.

ASSEMBLY

WARNING:

• When removing the heated final driven gear out of

the container, use tongs to avoid burning hands.

• While installing the heated final driven gear, use

oven gloves or similar to avoid burning hands.

CAUTION: Do not le ave the final drive n gear in boiling

water for longer than 5 minutes. Overheating the gear

may cause a reduction in gear strength.

1. Place the driven gear in a water container, heat and

remove when the water boils and dry off.

NOTE: After removing the moisture on the final driven gear,

install as quickly as possible.

2. Install the final driven gear (1), with the groove (2)

facing up, to the differential case.

3. Tighten the final gear bolts (1) to the specified torque.

NOTE: To prevent rust, apply A/T fluid to the final driven

gear after installation

DIFFERENTIAL GEAR THRUST PLAY 0.05 - 0.20 mm

FINAL GEAR BOLTS (a)

TORQUE SPECIFICATION 78 Nm

4. After applying A/T fluid to the output shaft speed

sensor (VSS) drive gear (1), install the output shaft

speed sensor drive gear.

5. Install a new differential side RH bearing (1) using

special tool 09913-70123 (A) and a hydraulic press.

NOTE: Replace the differential side RH bearing together

with the bearing cup as a set.

6. Install the new differential side LH bearing (1)using

special tool 09913-70123 (A) and a hydraulic press.

NOTE: Replace the differential side LH bearing together

with the bearing cup as a set.

COUNTERSHAFT

Legend

1. Countershaft RH bearing 4. Reduction driven gear Apply automatic transaxle

fluid.

2. Countershaft 5. Bearing cap

3. Countershaft LH bearing 6. Countershaft bearing shim Do not reuse.

DISASSEMBLY

1. Remove countershaft LH bearing (1) and reduction

driven ge ar (2) as one using spe cial tool 09925-9822 1

(A) and a hydraulic press.

2. Remove th e cou ntershaft RH bear ing (1) using specia l

tools 09913-61510 (A) and (B) 09926-58010.

ASSEMBLY

1. Install a new count er sh aft RH bearing ( 1) usi ng spec ia l

tool 09913-8451 (A) and a hydraulic press.

NOTE: R eplace th e countershaft RH bearing to gether with

the bearing cup as a set.

2. Install the reduction driven gear (1) with special tools

09913-84510 (A), 09925-88210 (B)

and a hydraulic

press.

3. Install countershaft LH bearing (1) with special tools

09913-84510 (A), 09925-88210 (B) and hydraulic

press.

VALVE BODY

Legend

CAUTION: When rep lacing the pressure co ntrol soleno id valve, it must be repl aced togeth er with the

valve body assembly as a set. Replacing the pressure control solenoid independently may cause

excessive shift shock.

1. Pressure control solenoid 5. Timing solenoid valve 10. O-ring

valve 6. Temperature sensor clamp Apply automatic transaxle

2. Shift solenoid valve-A (No.1) 7. Valve body assembly fluid.

3. Shift solenoid valve-B (No.2) 8. Manual valve Tightening torque

4. TCC (Lock-up) solenoid valve 9. Solenoid lock plate Do not reuse.

DISASSEMBLY

1. Pull out the manual valve (1).

2. Remove the pressure control solenoid valve (1) and

the solenoid lock plate (2).

3. Remove the TCC (Lock-up) solenoid valve (1).

4. Remove the shift solenoid valve-A (1).

5. Remove shift solenoid valve-B (1).

6. Remove the timing solenoid valve (1).

7. Remove the temperature sensor clamp (1).

ASSEMBLY

• Rev erse the di sass embly pr oced ure for asse mbly, not-

ing the following points.

• Shift solenoid valve-A and -B are identical

• After applying A/T fluid to the new O-rings, fit them to

the solenoid valves, then install the solenoid valves to

the valve body.

• Tighten the solenoid valve bolts to specified torque.

SOLENOID VALVE BOLTS (a) 11 Nm

BOLT LENGTH “A” PIECES

A (1) 49 mm 5

B (2) 20 mm 1

TORQUE CONVERTER HOUSING

Disassembly

1. Remove the fluid reservoir RH plate (1) and the lubri-

cation tube clamp (2).

NOTE: Do not bend the lubrication tube with excessive

force.

2. Remove the lubrication LH tube (1) and RH tube (2).

3. Remove the differential side oil seal (1).

4. Remove the countershaft RH bearing cup using special

tools 09944-96011 (A) and 09942-15511 (B).

5. Remove the differential side RH bearing cup using

special tools 09944-96011 (A) and 09942-15511 (B).

6. Remove the torque converter case plugs (1).

Assembly

1. After applying A/T fluid to the new O-rings, fit them to

the housing plugs. Finally install the plugs to the torque

converter housing.

2. Using spec ia l tool s 0992 4- 745 10 (A) and 0994 4-68210

(B), assemble the differential side RH bearing cup.

3. Using special tool 09913-75520, install the counter-

shaft RH bearing cup.

TORQUE CONVERTER HOUSING

PLUGS (a) 7.5 Nm

4. Using spec ia l tool s 0992 4- 745 10 (A) and 0994 4-88220

(B), install the new differential side oil seal to the torque

converter housing.

5. Apply grease to the oil seal lip.

Lithium grease

6. Install the lubrication LH tube (1) and RH tube (2).

7. Install the fluid reservoir RH plate (1) and the lubrica-

tion tube clamp (2).

DIFFERENTIAL SIDE OIL SEAL

INSTALLING DEPTH (a) 2.6 - 3.6 mm

LUBRICATION TUBE CLAMP BOLT (a)

TORQUE SPECIFICATION 5.5 Nm

FLUID RESERVOIR RH PLATE BOLTS

(b)

TORQUE SPECIFICATION 5.5 Nm

TRANSAXLE CASE

Disassembly

1. Remove the differential side oil seal (1).

2. Remove the countershaft LH bearing cup and shim

with special tools 09944-96011 (A) and 09942-15511

(B).

3. Remove the differential side L H bearing cup and shim

with special tools 09944-96011 (A) and 09942-15511

(B).

Assembly

1. Using spec ia l tool s 0992 4- 745 10 (A) and 0994 4-68210

(B), assemble the shim and differential side LH bearing

cup.

NOTE: Use a shim with same thickness as the one

removed.

2. Using special tools 09924-84510-002 (A) and 09913-

75821 (B), assemble the shim and countershaft LH

bearing cup .

NOTE: Use shim with the same thickness as the one

removed.

3. Install a new differential side oil seal to the transaxle

case using special tools 09924-74510 (A) and 09944-

88220 (B).

4. Apply grease to the oil seal lip.

Lithium grease

DIFFERENTIAL SIDE OIL SEAL

INSTALLING DEPTH (a) 3.8 - 4.8 mm

ADJUSTMENT BEFORE UNIT ASSEMBLY

Differential Side Bearing Preload

1. After applying A/T fluid to the differential assembly, fit it

to the transaxle case.

2. Install the torque converter housing to the transaxle

case, then tighten bolts (1) to the specified torque.

3. Measure the bearing preload (a) using special tool

09928-060 50 (A) .

4. If the bearing preload is out of specification, select a

shim with a suitable thickness from the list below and

replace it. Adjust the differential side bearing preload to

be within specification.

Available shim thickness

NOTE: Record the measured v alue (a), as i t is required to

adjust the counter shaft bearing preload.

5. Remove the differential assembly.

TORQUE CONVERTER HOUSING

BOLTS (a) 33 Nm

DIFFERENTIAL SIDE BEARING PRE-

LOAD (STARTING TORQUE) (a)

NEW BEARING

RE-USED BEARING 0.8 -1.4 Nm

0.4 - 0.7 Nm

THICKNESS IDENTIFICATION MARK

1.80 mm A

1.85 mm B

1.90 mm C

1.95 mm D

2.00 mm E

2.05 mm F

2.08 mm G

2.11 mm H

2.14 mm J

2.17 mm K

2.20 mm L

2.23 mm M

2.26 mm N

2.29 mm P

2.32 mm Q

2.35 mm R

2.40 mm S

2.45 mm T

2.50 mm U

2.55 mm V

2.60 mm W

2.65 mm X

2.70 mm Y

Counter Shaft Bearing Preload

1. Apply A/T fluid to the countershaft assembly (1) and

the differential assembly (2) before installation.

2. Install torque converter housing to the transaxle case,

then tighten bolts to specified torque.

3. Measure the bearing preload (b) by using special tool

09928-060 50 (A) .

Counter shaft bearing preload (c) = (b) – Differential side

bearing preload (a) as previously noted.

4. If the bearing preload is out of specification, select a

shim with a suitable thickness from the list below and

replace it. Adjust the countershaft bearing preload to

be within specification.

Available shim thickness

5. Remove the differential assembly and counter shaft

assembly.

TORQUE CONVERTER HOUSING

BOLTS

TORQUE SPECIFICATION 30 Nm

COUNTER SHAFT BEARING PRELOAD

(STARTING TORQUE) (c)

NEW BEARING

RE-USED BEARING 0.33 - 0.76 Nm

0.17 - 0.38 Nm

THICKNESS IDENTIFICATION MARK

1.70 mm 1

1.75 mm 2

1.80 mm 3

1.85 mm 4

1.90 mm 5

1.93 mm 6

1.96 mm 7

1.99 mm A

2.02 mm B

2.05 mm C

2.08 mm D

2.11 mm E

2.14 mm F

2.17 mm G

2.20 mm H

2.25 mm K

2.30 mm L

2.35 mm M

2.40 mm N

2.45 mm P

2.50 mm Q

2.55 mm R

2.60 mm S

2.65 mm U

2.70 mm W

4.6 UN IT ASSEMBLY

CAUTION:

• The automatic transaxle consists of precision parts. Even a flaw in a small part may cause oil leak-

age or a decrease in function, check each part carefully before installation.

• Clean all parts with compressed air. Never use cloths or rags.

• Before assembling new clutch or brake discs, soak them in A/T fluid for at least 2 hours.

• Always use new gaskets and O-rings.

• Lubricate O-rings with A/T flu id.

• Apply A/T fluid to sliding or rotating surfaces of parts before assembly.

• Lithium grease to retain parts in place.

• Be sure to install thrust bearings and races in the correct direction and position.

• Make sure that snap ring ends are not aligned with the cutouts and are installed in their groove

correctly.

• Do not use adhesive cements on gaskets or similar p arts.

• Be sure to torque each bolt and nut to specification.

1. Install a new m anu al s hi ft shaft oil seal to t he tr an sa xl e

case.

Use special tool 09925-98210 (A) and a hammer to

install, then apply grease to its lip.

“A”: Lithium grease

2. Install the manual detent spring (1) to the transaxle

case and tighten the manual detent spring bolt to

specified torque.

3. Install the parking lock pawl rod (2) to the manual valve

lever (1).

MANUAL SHIFT SHAFT OIL SEAL

INSTALLING DEPTH (a) 0.75 - 1.25 mm

“a”

(A)

“A”

MANUAL DETENT SPRING BOLT (a)

TORQUE SPECIFICATION 10 Nm

4. After applying A/T fluid to the new manual valve lever

(1), install new manual shift shaft (4), new spacer (3)

and manual valve lever to the transaxle case.

5. After installing the manual valve lever pin (2) using

spring pin remover with (3 mm diameter) (5) and a

hammer , turn spacer to set the position as shown in the

figure. Then stake the spacer with a punch.

6. Install the parking lock pawl bracket (1) to the transaxle

case.

7. After applying A/T fluid to the new O-rings, inner O-ring

(1) and outer O-ring (2), install them to the 1st and

reverse brake piston (3).

8. Install the 1st and reverse brake piston (1) to the

transaxle case (2).

NOTE: Be careful not to damage the O-ring when installing

the 1st and reverse brake piston.

PARKING LOCK PAWL BRACKET

BOLTS (a)

TORQUE SPECIFICATION 7.5 Nm

9. Install the 1st and reverse brake return spring subas-

sembly (1) to the transaxle case (2).

10. Apply A/T fluid to the 1st and reverse brake discs (2),

separator plates (3) and the retaining plate (1), then

install them to the transaxle case.

CAUTION:

Do no t damage th e 1st and revers e brake

return spring subassembly discs, plates and piston

by pressing in the 1st and reverse brake return

spring subassembly more than 0.8 mm past its orig-

inal installation position.

11. Compress the 1st and reverse brake return spring

using special tool 09926-97620 (A) and a hydraulic

press, then attach snap ring.

12. Install the 1st and reverse brake plate snap ring so that

its ends are positioned correctly.

[A] - Correct

[B] - Incorrect

13. Using sp eci al too ls 09 900-2 0607 ( A), 09 900 -2070 1 ( B)

and 09952-06020 (C), measure the 1st and reverse

brake piston stroke when compressed air (400 – 800

kPa) is blown through the oil hole (1).

CAUTION:

• Do not use the transaxle case as groundwork to

press fit the reduction drive gear, use a stand that

can lift the transaxle case slightly.

• Do not place a load of more than 20 kN with the

hydraulic press or the reduction drive gear bearing

may be damaged.

14. Install the reduction drive gear (1) to the transaxle case

(3) using special tools 09951-18210 (A) and 09944-

78210 (B) and a hydraulic press.

NOTE: When replacing reduction drive gear, replace it

together with reduction driven gear as a set.

15. Install the parking lock pawl (1) and spring (2). Apply A/

T fluid to the park ing lock pawl shaft, then insert it into

the transax le case.

CAUTION:

• Do not reuse the planetary ring gear subassembly

or it may cause damage to the planetary gear unit

and/or the reduction gears.

• Do not use the transaxle case as groundwork to

press fit the planetary ring gear subassembly, use

a stand that can lift the transaxle case slightly.

• Do not place a load of more than 20 kN with the

hydraulic press or it may damage the reduction

drive gear bearing.

16. Install a new planetary ring gear subassembly (1) to

the reduction drive gear (3) using special tools 09951-

18210 (A), 09944-78210 (B) and a hydraulic press.

1ST AND REVERSE BRAKE PISTON

STROKE STANDARD 0.791 - 1.489 mm

CAUTION:

• Do not exceed specifications when tightening the

reduction drive gear nut or nut may break.

• Carry out this procedure on a rubber mat to avoid

damaging the transaxle case.

17. Tighten the new reduction drive gear nut to the

planetary ring gear subassembly gradually until the

reduction drive gear bearing preload is within

specification.

18. Stake the reduction drive gear nut (1).

19. Apply A/T fluid to the planetary gear assembly (1), then

fit it to the planetary ring gear assembly.

REFERENCE

TORQUE SPECIFICATION 100 Nm

REDUCTION DRIVE GEAR BEARING

PRELOAD (STARTING TORQUE)

STANDARD 0.05 - 0.35 Nm

20. Check for correct installation of the planetary gear

assembly as follows.

Measure the distance (a) using a micrometer caliper

(1) and a str aig hte dge (2 ). If th e m eas ured va lu e i s o ut

of specification, remove the planetary gear assembly

and reinstall it correctly.

21. Apply A/T fluid to the one-way clutch No.2 assembly

(1), then install it to the planetary gear assembly.

Ensure that the planetary carrier rotates in a counter-

clockwise direction (A) only, not in a clockwise direction

(B).

22. Install the one-way clutch outer race retainer (1).

DISTANCE BETWEEN PLANETARY

GEAR ASSEMBLY AND MATING SUR-

FACE OF TRANSAXLE CASE (a) MORE THAN

49.9 mm

“a”

23. Apply A/ T fluid to the new brak e drum gask et (1), then

install it to the transaxle case.

24. Apply A/T fluid to the 2nd brake retaining plate (1),

discs (2) and separator plates (3), then install them to

the transax le case.

25. Install the 2nd brake return spring subassembly (1) to

the transax le case.

26. Apply A/T fluid to the 2nd brake piston assembly (1),

and align the projection of the 2nd brake piston

assembl y with the groove on the transaxle c ase, then

fit together.

CAUTION: Do not damage the 2nd brake piston assem-

bly, return spring subassembly, plates and discs by

pressing in the 2nd brake a ssembly more than 0.4 mm

past its original installation position

27. Install 2nd brake piston snap ring (1) by using special

tool 09926-96050 (A) and hydraulic press.

28. Check the 2nd brake piston stroke by measuring the

clearance between the 2nd brake separator plate (1)

and the piston (2) with a feeler gauge (3).

If the clearance (piston stroke) is out of specification

replace the clutch discs and plates with new ones.

CAUTION: When component parts of the 2nd brake

(namely brake disc, retaining plate and/or separator

plate) have been re-pla ced, all lear ned contents, which

have been stored in TCM memory by executing learn-

ing control, should be initialised, refer to

3.12 TRANSMISSION CONTROL MODULE - LEARNING

CONTROL INITIALISATION in this Section.

Neglectin g this init ialis atio n may ca u se ex ces sive shift

shock.

29. After applying A/T fluid to the front sun gear thrust

bearing race (2), install it to the front planetary sun

gear (1).

30. Apply A/T fluid to the front planetary sun gear (1) and

install it to the planetary gear assembly (2).

CAUTION: Be sure to install the O/D and 2nd coast

brake retaining plate snap ring correctly in the groove

in the transaxle case.

31. Install the O/D and 2nd coast brake retaining plate

snap ring (1).

2ND BRAKE PISTON STROKE

STANDARD 0.40 - 1.25 mm

32. After applying grease to the slide contact face of the

planetary carrier thrust washer (1), install it to the

planetary gear assembly.

(A): Lithium grease

33. Apply A/T fluid to the one-way clutch No.1 assembly

(3) and install the one -way clutc h No.1 ass embly (3) to

the rear planetary sun gear subassembly (2).

34. Apply A/ T fluid to the plan etary gear th rust bearing (1) ,

then install it to the one-way clutch No.1 assembly (3).

35. After applying A/T fluid to the rear planetary sun gear

subassembly and the one-way clutch No.1 assembly

(1), install them in the transaxle case (2).

36. After applying A/T fluid to the rear sun gear thrust

bearing race (1), install it to the rear planetary sun gear

(2).

37. After applying A/T fluid to the rear sun gear thrust

bearing (1), install it to the forward clutch hub (2).

38. After applying A/T fluid to the forward clutch hub (1),

install it in the transaxle case (2).

39. After applying A/T fluid to the interme diate shaft thrust

bearing rear race (3), thrust bearing (2) and front race

(1), install them to the forward and reverse clutch

assembly (4).

Bearin g race dimension

40. Apply A/T fluid to the forward and reverse clutch

assembly (1).

Install the forward and reverse clutch assembly by

rotating clockwise and counter clockwise frequently to

fit the clutch discs to the mating hubs.

NOTE: Before installation, align the teeth of the forward

and reverse clutch discs to ease installation.

41. Check for correct installation of the forward and

reverse clutch assembly as follows.

Measure distance “a” using a micrometer caliper (1)

and straightedge (2). If the measurement is out of

specification, remove the forward and reverse clutch

assembly, forward clutch hub, rear planetary sun gear

subassembly and one-way clutch No.1 assembly and

reinstall them cor rectl y.

FRONT RACE REAR RACE

OUTSIDE DIAMETER 30.6 mm 28.2 mm

THICKNESS 2.0 mm 2.0 mm

DISTANCE BETWEEN FORWARD AND

REVERSE CLUTCH ASSEMBLY AND

MATING SURFACE OF TRANSAXLE

CASE (a) LESS THAN

29.4 mm

“a”

42. After applying A/T fluid to the O/D and 2nd coast brake

retaining plate (4), separator plate (3), discs (2) and

rear plate (1), install them to the transaxle case (5).

43. Measure the O/D and 2nd coast brake piston stroke.

• Measure dimension (a) from the end face of the tran-

saxle case to the O/D and 2nd coast brake rear plate

(1) using a straightedge and a micrometer caliper.

• Measure dimension (b) from the O/D and 2nd coast

brake piston (2) to the rear cover assembly mating sur-

face using a straightedge and a micrometer caliper.

• Cal cul ate the piston str oke fr om the mea su red val ue of

dimensions (a) and (b).

• Piston stroke = (a) – (b))

When the piston stroke is out of specification, select the

O/D and 2nd coast brake rear plate with correct thickness

from the list below and replace it.

Available O/D and 2nd coast brake rear plate thickness

CAUTION: When the component parts of the O/D and

2nd coast brake (namely brake disc, retaining plate,

separator plate and/or rear plate) have been replaced,

learned contents, which have been stored in the TCM

memory by executing l ear ning c ontrol , should be initi-

alised referring to LEARNING CONTROL

INITIALISATION in 3.12 TRANSMISSION CONTROL

MODULE in this Section.

Neglectin g this init ialis atio n may ca u se ex ces sive shift

shock.

O/D AND 2ND COAST BRAKE PISTON

STROKE STANDARD 0.65 - 1.05 mm

THICKNESS IDENTIFICATION MARK

1.8 mm 1

2.0 mm 2

2.2 mm 3

2.4 mm 4

2.6 mm 5

44. After applying A/T fluid to the new 2nd brake gaskets

(1), install them to the transaxle case (2).

45. After applying A/T fluid to the reverse clutch drum

thrust bearing (1), install it to the forward and reverse

clutch assembly (2).

46. Remove the sealant attached to the mating surface of

the transaxle re ar cove r (1 ) thorou ghly.

47. Apply sealant to the mating surface of the transaxle

rear cover (1) by using a nozzle (2) which will give a

sealant bead 1.2 mm in diameter as shown in the

figure.

“A”: Sealant Three Bond No. 1216B

48) Install transaxle rear cover assembly on transaxle

case.

49. Install hook (2) to location as shown in the figure.

50. Tighten the rear cover bolts (1).

51. Install the fluid reservoir LH plate (1).

“A”

REAR COVER BOLTS (a) 25 Nm

FLUID RESERVOIR LH PLATE BOLT (a)

TORQUE SPECIFICATION 10 Nm

52. After applying A/T fluid to the new governor apply No.2

gasket (1), install it in the transaxle case.

53. After applying A/T fluid to the differential assembly (1)

and the countershaft assembly (2), install them to the

transaxle case.

54. After applying A/T fluid to the direct clutch hub (1),

install it to the planetary gear assembly.

55. After applying A/T fluid to the input shaft rear thrust

bearing (1) and thrust bearing race (2), install them into

the direct clutch hub (3).

56. After applying A/T fluid to the input shaft front thrust

bearing (1), install it to the direct clutch assembly (2).

57. Apply A/T fluid to the direct clutch assembly (1).

Install the direct clutch assembly by rotating clockwise

and counter clockwise frequently to fit the clutch discs

to the mating hub.

NOTE: Before installation, align the teeth of the direct

clutch discs to ease installation.

58. Check for correct installation of the direct clutch

assembly as follows.

Measure distance “a ” by using a mic r om eter caliper (1)

and straighte dge (2). If out of speci fica tion , r emo ve th e

direct clutch assembly, direct clutch hub and reinstall

them correctly.

59. Install the oil pump assembly to the transaxle case.

DISTANCE BETWEEN DIRECT

CLUTCH ASSEMBLY AND MATING

SURFACE OF TRANSAXLE CASE (a) 10.4 - 11.4 mm

“a”

OIL PUMP ASSEMBLY BOLTS (a)

TORQUE SPECIFICATION 25 Nm

60. Make sure that the input shaft (1) turns smoothly.

61. Measure the input shaft thrust play.

Apply a dial gauge onto the input shaft end (1) and

measure the th ru st p lay of the i npu t sh aft usin g s pec ia l

tools 09900-20607 (A) and 09900-20701 (B).

62. After applying A/T fluid to the new O-ring, fit it to

breather union (2). Install the breather union to the

transaxle case.

63. Install the breather hose (1).

64. Wipe off and clean the mating surface between the

transaxle case (1) and the torque converter housing.

65. Apply sealant to the torque converter housing (1) using

a nozzle (2) which will give a sealant bead 1.2mm in

diameter as shown in the figure.

“A”: Sealant Three Bond No. 1216B

INPUT SHAFT THRUST PLAY 0.3 - 0.9 mm

“A”

CAUTION: Apply sealant to the threads of the four

bolts as shown in the figure before tightening.

“A”: Sealant Three Bond No. 1216B

66. Install the torque converter housing to the transaxle

case, tighten bolts to specified torque.

67. After applying A/T fluid to the new O-ring, fit it to the

transaxle case plug (1).Install the transaxle case plug

to the transaxle case (2).

TORQUE CONVERTER HOUSING

BOLTS (a)

TORQUE SPECIFICATION 33 Nm

TRANSAXLE CASE PLUG (a)

TORQUE SPECIFICATION 7.5 Nm

68. Install the new O-r ings to ea ch accumu lator piston and

apply A/T fluid to them.

Accumulator O-ring dimension

NOTE: Make sure that the O-rings are not twisted or

pinched when installing

69. Install B1, C1, C2 accumulator pistons and springs.

Accumul ator piston identification

Accumulator spring identification

70. After applying A/T fluid to the cooler check valve (1)

and spring (2 ), install them to the trans ax le case (3 ).

O-RING NAME INSIDE

DIA. SECTION

DIA.

B1 ACCUMULATOR O-RING (LARGE) (2)

C1 ACCUMULATOR O-RING (LARGE) (2)

C2 ACCUMULATOR O-RING (LARGE) (2)

(ABOVE THREE O-RINGS ARE SAME.) 29.4

mm 2.6 mm

B1 ACCUMULATOR O-RING (SMALL) (4) 19.7

mm 2.6 mm

C1 ACCUMULATOR O-RING (SMALL) (6)

C2 ACCUMULATOR O-RING (SMALL) (6)

(ABOVE TWO O-RINGS ARE SAME.) 21.8

mm 2.6 mm

PISTON NAME

IDENTIFICATION

(EMBOSSED LETTERS

ON PISTON)

B1 ACCUMULATOR PISTON

(3) SB-1

C1 ACCUMULATOR PISTON

(5) S2C-1

C2 ACCUMULATOR PISTON

(8) S2C-2

SPRING NAME

COLOUR OF

IDENTIFICATION

PAINT

B1 ACCUMULATOR NO.2 SPRING (1) PINK

C1 ACCUMULATOR NO.2 SPRING (7) LIGHT BLUE

C2 ACCUMULATOR NO.2 SPRING (9) YELLOW

71. After applying A/T fluid to the new governor apply No.1

gasket (1), install it to the transaxle case.

CAUTION: When installing the valve body harness (1)

into the transaxle case, take care not to damage the

transmission fluid tempe rature sensor (2 ) at the narr ow

entrance to the case.

Careless s ensor tr eatment may cause se nsor malfun c-

tion.

72. After applying A/T fluid to the new O-ring, fit it to the

valve body harness connector (3), then install the valve

body harness to the transaxle case.

73. Install the manual valve rod (1) to the manual valve

lever (3) then install the valve body assembly (2) to the

transaxle case.

VALVE BODY HARNESS CONNECTOR

BOLT (a) 5.5 Nm

74. Tighten the valve body bolts to the specified torque.

Valve body bolt length

75. Connect the solenoid connectors to the solenoid

valves, identifying their installation positions by the wire

colours, then install the transmission fluid temperature

sensor to its clamp.

76. Install the oil strainer assembly (1).

VALVE BODY BOLTS

TORQUE SPECIFICATION 11 Nm

BOLT LENGTH (A) PIECES

A (1) 20 mm 6

B (2) 28 mm 5

C (3) 49 mm 1

D (4) 36 mm 1

E (5) 40 mm 1

SOLENOID VALVE CONNECTOR WIRE

COLOUR

SHIFT SOLENOID VALVE-A (1) WHITE

SHIFT SOLENOID VALVE-B (2) BLACK

TIMING SOLENOID VALVE (3) YELLOW

TCC (LOCK-UP) SOLENOID VALVE (4) LIGHT

GREEN

PRESSURE CONTROL SOLENOID VALVE (5) GRAY +

GREEN

TRANSMISSION FLUID TEMPERATURE

SENSOR (6) ORANGE

OIL STRAINER BOLTS (a) 10 Nm

77. Install the oil cleaner magnets (1) in oil pan (2).

NOTE: If metal particles are attached to the magnets, clean

them before installing.

78. Install a new oil pan gasket (1) between the transaxle

case and the oil pan (2).

79. After applying A/T fluid to the new O-ring, fit it to the

fluid outle t union (1). Ins tall the fluid outlet uni on to the

transaxle case.

80. Install the new gasket then install the fluid cooler pipes.

81. After applying A/T fluid to the new O-ring, fit it to the

fluid filler tube. Install the fluid filler tube to the

transaxle case.

OIL PAN BOLTS (a)

TORQUE SPECIFICATION 7.0 Nm

FLUID OUTLET UNION (a)

TORQUE SPECIFICATION 25 Nm

FLUID COOLER PIPE FLARE NUT (b)

TORQUE SPECIFICATION 35 Nm

FLUID COOLER PIPE BOLT (c)

TORQUE SPECIFICATION 22 Nm

FLUID COOLER PIPE BRACKET

BOLT (d)

TORQUE SPECIFICATION 10 Nm

FLUID FILLER TUBE BOLT (e)

TORQUE SPECIFICATION 10 Nm

82. Apply A/T fluid to the O-rings of each sensor and install

the input shaft speed sensor (1) and the output shaft

speed sensor (VSS) (2).

83. Install the harness bracket (3) and the select cable

clamp (4).

84. Install the transmission range sensor to the transaxle

case, tighten bolts temporarily at this step.

85. Install the lock washer (1) and tighten the lock nut (2)

to specified torque.

INPUT SHAFT SPEED SENSOR BOLT

(a)

TORQUE SPECIFICATION 5.5 Nm

OUTPUT SHAFT SPEED SENSOR (VSS)

BOLT (b)

TORQUE SPECIFICATION 13 Nm

HARNESS BRACKET BOLTS (c)

TORQUE SPECIFICATION 23 Nm

SELECT CABLE CLAMP BOLT (d)

TORQUE SPECIFICATION 10 Nm

TRANSMISSION RANGE SENSOR

LOCK NUT (a) 7 Nm

86. Install the manual select lever (1) temporarily at this

step.

87. After shifting the manual select lever fully counterclock-

wise, select the N range position by moving it back 2

notches clockwise.

88. Remove the manual select lever (1) at this step.

89. Loosen th e sensor b olts and al ign the ne edle dire ction

shaped on lock washer (2) with the N reference line (3)

on the transmission range sensor by moving the

sensor in circular direction.

90. Tighten the sensor bolts to specified torque.

91. Bend the dents of the lock washer (1) to secure in

position.

92. Install the manual select lever (1).

TRANSMISSION RANGE SENSOR

BOLTS (b)

TORQUE SPECIFICATION 5.5 Nm

MANUAL SELECT LEVER NUT (a)

TORQUE SPECIFICATION 13 Nm

93. Install the engine mount LH bracket (1).

CAUTION:

• Before installing the torque converter, ensure its

pump hub portion is free from nicks, burrs or dam-

age which may cause the oil seal to leak.

• Do not drop the torque converter ont o the oil pump

gear.

Damage to the gear, may cause serious problems.

• Ins tall the tor que conver ter, alig ning the grooves (1) of

the torque converter and the projection (2) of the oil

pump drive gear.

• Install the torque converter (3), taking care not to the

damage oil seal on the oil pump.

• After ins talling the torq ue conver ter, che ck that the di s-

tance (a) (measured from the flange nut (4) to the

torque converter housing (5) mounting surface) is

within sp ec ifica t io n.

• Check the torque converter for smooth rotation.

• Apply grease around the cup (6) at the centre of the

torque converter.

“C”: Lithium grease

ENGINE MOUNT LH BRACKET BOLTS

(a)

TORQUE SPECIFICATION 50 Nm

TORQUE CONVERTER INSTALLING

POSITION (a) MORE THAN

19.9 mm

5. SPECIAL TOOLS

NOTE: Refer to Section 0A GENERAL INFORMATION — 7. CONSOLIDATED TOOLS for a detailed list of

special tools and the local equivalent if one is available.

09900-20605 09900-20607 09900-20701 09913-50121

Dial caliper gauge Dial gauge Magnetic stand Oil seal remover

09913-61510 09913-70123 09913-75520 09913-75821

Bearing puller Bearing installer Bearing installer Bearing installer handle

09913-84510 09913-85210 09923-78210 09924-74510

Bearing installer Bearing installer Bearing installer Bearing installer handle

09924-84510-002 09925-37811-001 09925-88210 09925-98210

Bearing installer Oil pressure gauge Bearing puller attachment Bearing installer

09925-98221 09926-37610 09926-37610-001 09926-37610-002

Bearing installer Bearing remover

See NOTE 1. Bearing puller

See NOTE 2. Bearing pul ler att achment

See NOTE 2.

09926-37610-003 09926-58010 09926-96030 09926-96050

Bearing remover attach-

ment

See NOTE 2.

Bearing remover attach-

ment Clutch spring compressor Brake piston compressor

09926-97610 09926-97620 09926-98310 09928-06050

Spring compressor Spring compressor Clutch spring compressor Differential preload

adapter

09942-15511 09944-68210 09944-78210 09944-88220

Sliding hammer Bearing installer Bearing installer support Oil seal installer

NOTE:

• “1”: This tool consists of Bearing Puller with 09926-37610-001, Bearing Puller Attachment with 09926-

37610-002 and Bearing Remover Attachment with 09926-37610-003.

• “2”: This tool is constituent of Bearing Remover with 09926-37610.

6. REQUIRED SERVICE MATERIAL

09944-96011 09946-06710 09951-18210 09952-06020

Bearing outer race

remover Bearing retainer dummy Oil seal installer Dial gauge plate No.2

Material Recommended product Use

Automatic transmission fluid An equivalent of DEXRON

-III

• Automatic transaxle

• Parts lubrication when installing

• O-rings

Sealant Three Bond No. 1216B

• Mating sur face of torque con-

verter ho usi ng

• Mating surface of rear cover

assembly

• Torque converter housing bolts

• Drive plate bolts

Lithium grease Lithium Grease

• Oil seal lips

• Pl an etary carrie r th rus t wa she r

Lithium Grease

• Cable ends

• Converter centre cup